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So the looks of this doesn't really matter seeing they will not be a visible component after insertion. Is the outer covering just to protect the foam?

basically correct - doesnt need to look 'incredible' as its just covering foam but needs to look adequately professional

the vacuumed idea is intriguing but i have no experience with that so trying to picture how it would work - the enclosed tubes will be used to firm up inner springs (they will not be visible apart from initial insertion)

ok here goes:

i am trying to produce a sort of foam rod insert to be used to stabilize innerspring units. I got the foam rod the size and width i wanted, its about two feet long, but they need to be covered in order to look appealing to the final consumer. (also: the rod will never have to come out or be removed from the cover - we only have to insert and close it once)

I'm having trouble thinking of a cost (and time) effective way to enclose these rods and my only current solution can be seen on the link - i have sort of sewn an enclosure out of polyester and put a zipper in the middle where the rod can get inserted - however this is sloppy (have to fold the rod to get it in there and time-consuming; not even to mention that it puts quite the stress on the seams when inserting. i have attached pics of the rod, the current cover with the zipper, so you can see the basic design below i have racked my brain but cannot come up with a better alternative - perhaps some kind of snap/flap on one of the ends where you can just insert and close? im at a loss and any ideas would be much, much appreciated - pictures of current setup below - any advice or help appreciated!

http://imgur.com/a/XEzyE