Custom Foam Inserts For Cases

Custom foam inserts are essential for protecting valuable equipment from impacts, drops, and vibration. While a quality protective case shields from external elements, it's the precision-cut foam interior that provides the critical cushioning and organization your equipment needs.

At Production Case, we combine over 30 years of technical expertise with advanced manufacturing capabilities to create premium custom foam solutions. Our in-house Canadian facility handles everything from design through manufacturing, ensuring exceptional quality control and quick turnaround times.   

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Our Custom Foam Process

Our in-house design and manufacturing team can create precise custom foam interiors and inserts for almost any brand or use. We can also use your design files to make them exactly how you need them.

Whether you need it for a Pelican, Nanuk, SKB or custom case, Production Case has you covered!

From a single custom foam insert to runs of hundreds, we’ll deliver what you need.

Our process for designing and creating your custom foam includes: 

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1. Our Expert Consultation

  • In-person or virtual evaluation of your equipment 
  • Assessment to meet superior protection requirements 
  • Discussion of usage environment and conditions 
  • Material and design recommendations 

2. Precision Foam Design

  • CAD modelling for a snug fit
  • Optimization for maximum protection 
  • Client review and approval 
  • Manufacturing specifications preparation 

3. Canadian Quality Manufacturing

  • Premium material selection 
  • CNC precision cutting 
  • Rigorous quality inspection 
  • Secure handling throughout 

4. Final Inspection & Delivery 

  • Comprehensive quality check 
  • Fit testing with equipment (when possible) 
  • Secure packaging 
  • Delivery coordination 

We operate a fully equipped, Canadian-based facility, giving us complete control over the design, cutting, and assessment process. Our in-house design and manufacturing mean we can meet tight deadlines and deliver exceptional craftsmanship.

WHY INVEST IN A CUSTOM FOAM INSERT?

We can manufacture your custom inserts using the best type of foam for your case. The options we use include: 

Cross-Linked Polyethylene (XLPE)

  • Our premium dense foam choice 
  • Superior impact protection 
  • Professional finish 
  • Ideal for high-value equipment 
  • Excellent chemical resistance 
  • Perfect for long-term protection 
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Convoluted Polyurethane

  • Even pressure foam distribution 
  • Perfect for case lids 
  • Additional anti-static foam protection 
  • Customizable density 
  • Ideal for fragile equipment 
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Polyethylene

  • Firm and durable 
  • Water-resistant properties 
  • Great for heavier equipment 
  • Cost-effective protection 
  • Ideal for tools and firearms 
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Polyurethane

  • Soft cushioning properties
  • Perfect for delicate electronics 
  • Excellent shock absorption 
  • Cost-effective solution 
  • Ideal for lighter items 
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The best foam for cases depend on what you need to protect, and your budget. The weight and value of the equipment you’re protecting inside the case can help you decide, and our experts can also help you make a decision. 

Industries We Serve

Our custom foam solutions protect critical equipment across numerous sectors: 

Military & Defense

  • In-person or virtual evaluation of your equipment 
  • Assessment to meet superior protection requirements 
  • Discussion of usage environment and conditions 
  • Material and design recommendations 

Military & Defense

  • CAD modelling for a snug fit
  • Optimization for maximum protection 
  • Client review and approval 
  • Manufacturing specifications preparation 

Entertainment & Performance

  • Premium material selection 
  • CNC precision cutting 
  • Rigorous quality inspection 
  • Secure handling throughout 

Industrial & Professional 

  • Comprehensive quality check 
  • Fit testing with equipment (when possible) 
  • Secure packaging 
  • Delivery coordination 

The Production Case Advantage

  • Precision design and manufacturing 
  • Advanced cutting techniques 
  • Premium material selection 
  • Comprehensive quality assurance 

Why Choose Custom Foam Inserts?

Custom foam inserts protect your valuable equipment from jostles, drops, and shocks by keeping it snug and securely in place.

A solid protective case will shield your gear and protect it from the elements, but it’s the foam inserts and interior that will hold each piece and soften impacts.

At Production Case, we use precision design and machining along with high-end materials to create the most protective foam inserts possible. Our custom foam inserts will organize, cradle, and protect your delicate gear against impact, vibration, and moisture. 

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  • Complete in-house design and manufacturing in Ottawa 
  • Premium materials sourced from Canadian suppliers 
  • Rigorous quality control at every step 
  • Quick turnaround capabilities for urgent needs 

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With years of experience delivering custom cut foam inserts to different industries and our own in-house production and design team, Production Case is your best choice for custom foam case interiors and inserts.

Request a personalized quote and find out how we can work together to protect your valuable equipment inside any off-the-shelf or custom case. 

How to Cut Your Own Custom Foam Inserts

Production Case's in-house CAD/CAM expertise and CNC (computer numerical control) foam cutting equipment allow us to cut incredibly intricate and complex pockets to protect our clients’ sensitive case equipment. We are often challenged to produce custom foam cases that will ultimately protect many thousands of dollars’ worth of equipment.

But the average person like you and me may not be able to afford to absorb the one-time engineering costs to produce a CNC cut foam piece for one or two cases. That doesn’t mean we are left without options: with a reasonable amount of manual dexterity and some time, you can create your own custom foam case inserts.

When it comes to the best types of foam inserts, pick ‘n pluck foam is by far the easiest and most often used method to produce pockets in personal equipment cases. Most Pelican Storm, SKB and Pelican injection molded cases come with pick and pluck (or cubed foam). 

These pre-scored pluck foam pieces come in different layer thicknesses. Depending on the size of the case there may be anywhere from one to six or seven foam layers in a case.

There is typically one solid piece on the bottom of these cases which should never be cut through. Some of these cases will come with soft layered foam inside instead of pluck foam, so check the description for each case model.

When it comes to the best types of foam inserts, pick ‘n pluck foam is by far the easiest and most often used method to produce pockets in personal equipment cases. Most Pelican Storm, SKB and Pelican injection molded cases come with pick and pluck (or cubed foam). 

These pre-scored pluck foam pieces come in different layer thicknesses. Depending on the size of the case there may be anywhere from one to six or seven foam layers in a case.

There is typically one solid piece on the bottom of these cases which should never be cut through. Some of these cases will come with soft layered foam inside instead of pluck foam, so check the description for each case model.

Again, remember to leave an appropriate amount of foam between each piece. Place the more fragile pieces away from the sides of the case if possible. Cables and cords can go nearest the inside walls.

Toothpicks or any such tool may be used. Each piece will probably require different depths, so be careful to only pluck out to the desired depth. You can place the plucked out pieces back under the equipment to adjust for the desired height.

With a little ingenuity and a bit of patience you can achieve some wonderful results and guarantee your equipment will have a safe home for many years to come.