How to Make Custom Foam Inserts

Foam inserts are one of the most versatile and effective methods of protecting valuable items from foreign object damage. Foam can be seamlessly customised to fit all sizes of cases and boxes to safely hold your goods. Whether you need to protect your goods in transit, reduce the number of items going missing, or to have a bespoke presentation case, then foam is the ideal choice.

When opting for a custom foam insert, there are two types of foam available:
  • Open cell foam (polyurethane) – a more spongey, softer foam capable of manufacturing into 2D custom shapes that can be glued up in layers.
  • Closed cell foam (polyethylene) – a firmer, rigid foam able to cut 3D inserts from a single piece of foam. Plastazote is a commonly used brand of foam for inserts although there are more cost-effective products available.
If you are looking for a DIY option, then opt for an open cell foam. Either packaging foam (RP21-250) or 6lb recon that offer the greatest protection. To do this yourself:
  • Select a foam thickness that is deep enough to cover at least half the depth of your item (choose full depth for a secure hold; choose half depth or more to have the item sitting proud)
  • First cut the foam to fit inside your case or box Be mindful of rounded edges and/or wheels in the case. You may need to cut notches or use coins/rounded items to create rounded edges
  • Then, use chalk to draw around the outers of your good(s)
  • Use a short, small knife or scalpel to cut through the foam. The foam will cut easily, so try to slice the foam in neat layers for a better finish
  • Remember, you will also need to factor in layers of foam to the base and lid of the case!
  • You can opt to use a foam spray adhesive to secure the foams together
If you are a searching for a professional solution, then contact us for more information. Dependent on your budget and goods, you can opt for either packaging foam (RP21-250) or closed cell foam. The information we will need include:
  • As many dimensions (length x width x depth) as possible, including the external edges and internal pockets
  • Brief description on the requirements of the insert, i.e. transit foam, tool box foam, drone case insert, etc.
  • We can happily accept CAD files too (.dxf or .pdf)
  • Anthracite, coloured, or shadow boarded foam - a visual management technique for tool control
  • Whether you need egg box foam or alternative to fill a case lid.
If you are a trade business or ordering in volume, then please get in touch for trade prices.

For further information on custom foam inserts then please see our FAQ below:

What are foam inserts used for?

Foam inserts are widely used in cases, boxes and totes to protect goods in transit, in tool control, or to showcase valuable goods

What grade of foam is best for tool box foam?

Closed cell foam is generally a more expensive option suited to protecting fragile or bespoke fitted goods due to its more durable, rigid hold and being far more customisable. Open cell foam is usually a cheaper alternative but limited to simpler, 2D shapes

I already have a case – can I buy foam to fit?

By all means! Please get in touch and share your requirements and dimensions, and we will happily help

How can I find coloured foam with black foam top?

This is a shadow boarded foam commonly seen in by manufacturers and engineers as a quick and functional method of tool control

What colours foams are available?

Anthracite (black), red, yellow, blue and green

What types of case inserts have we manufactured?

We have created cases for flight cases, drones, Playstation or Xbox carry cases, cameras, watches, museums amongst others!

What case should I choose for my foam inserts?

Foam is suitable for Peli; Storm; Explorer cases and more

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