a method and apparatus of foam molding packaging using a positive vertical mold is provided in which a vertical mold with sides having channeled vertical flap areas is automatically covered with a plastic sheet . brushes , assisted by a vacuum assure the plastic sheet conforms to the mold including the flap areas . an open - ended carton having upper and lower flaps is placed over the mold so that the lower flaps are disposed vertically and cover the vertical flap areas . foam precursors are dispensed into the carton and its top sealed to allow foaming within the carton . the carton is then removed from the mold with the foam cushioning fully formed therein including the carton flaps which cover the top of the article to be packaged therein .