The NewAir I.B. ® Express system quickly creates Barrier Bubble® material that can be used for cushioning, and blocking and bracing applications. The system allows operators to create cushions with widths of 12 and 24 inches. In addition to offering a variety of film sizes, the system includes options for film strength to accommodate a variety of applications. By creating packaging materials on-site and on-demand the system eliminates the need to store large amounts of bulky materials, saving space while reducing material handling. The compact size and speed of the system allows operators to create inflatable cushions at workstations, online or for batching processes.