A method for filling the internal cavity of an appliance cabinet with an expanding foam material includes defining a pattern of fill holes in the outer cabinet wall at defined locations for injecting foam into identified sections of the cavity. Measured quantities of the foam material are injected into the fill holes in a sequential manner starting at one end of the cabinet and working towards an opposite end of the cabinet so as to sequentially deposit measured amounts of the foam material into the cavity against previously deposited sections of foam along the length of the cabinet while driving air within the cabinet towards a last section of the cabinet to be filled.