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Custom foam inserts
cut to your gear

Send us the case, the gear, or just the measurements. We design the layout and CNC-cut the foam to fit, from a single one-off to a 500-unit run. 20+ years of case-making in Bayswater, Melbourne. Shipped Australia-wide.

Send us your case size Call 03 9720 2550

Free to ask, no obligation to buy.

Foam inserts cut
10K+
One-off to 500+ units
No min
Of case-making
20+ yrs
Made in Bayswater, VIC
AUS

Trusted by industry leaders

Cases and inserts for defence, broadcast, emergency services and mining teams across Australia.

  • Australian Defence Force
  • ABC Television
  • Channel 9
  • NSW Ambulance
  • Qantas
  • BHP
  • Siemens
  • CSL Limited
  • Google
  • Mercedes Benz
  • Moto GP
  • Universities Australia

Any brand, any case

Supply your own case or pair with one of ours. We CNC-cut foam to exact tolerances for any brand, model or size. No gaps, no movement, no damage.

  • Pelican
  • Gator
  • SKB
  • HPRC
  • Nanuk
  • Explorer
  • + yours
Any dimension
Fits any internal case size
Case or specs
Send the case or just measurements
All densities
Budget EPE to premium closed-cell
Lead times
Contact us for current lead times
Quote my insert

Dimensions or a photo is enough. No CAD files needed.

Need the case too? See our custom road cases. Kitting out a tool chest? Read the tool box foam inserts guide.

Foam inserts for every case type

  • Hard cases

    Pelican, Nanuk, SKB

  • Flight cases

    Road, rack, ATA

  • Tool boxes

    Drawers, trays, kits

  • Storage cases

    Bins, trunks, boxes

  • Gun cases

    Rifle, pistol, safe

  • Instrument cases

    Guitar, camera, AV

Two ways to kit your Pelican

Genuine Pelican-made foam or a fully custom design. We cover every Pelican, Storm and Air case model.

  • A genuine Pelican replacement foam set

    Off the shelf

    Genuine Pelican foam

    Factory replacement foam sets made by Pelican for your exact model, ready to drop straight in.

    Shop replacement foam
  • A custom CNC-cut foam insert holding tools in a Pelican case

    Made to order

    Custom Pelican case foam

    CNC-cut and CAD-designed to your gear: exact cavities, clean edges, and kit that stays still in transit.

    Quote a custom Pelican insert

Why go custom

Plenty of hard cases ship with pick & pluck: a block of pre-scored cubes you tear out by hand. A CNC insert is cut to the outline of your gear.

CNC-cut foam compared with pick & pluck foam
Pick & pluck Torn out by hand CNC cut Recommended Cut to your gear
Shapes Limited to simple shapes Complex shapes possible
Edges Rough, uneven edges Clean, professional edges
Under load Compresses easily Maintains structural integrity
Over time Degrades over time Longevity and durability
Fit & finish Looks unprofessional Perfect fit every time

Replacing pick & pluck? Send the case model and we'll cut an insert to fit it.

From file to foam

CAD files, a sketch, or the gear itself. Whatever you start with, it's designed, cut and checked in our Bayswater workshop.

  1. Send your files

    Send us your DXF or DWG outline files, your desired layout, or cut-ready CAD files to work from.

    or

    Bring the gear

    Don't have design files? Bring in your equipment and we'll measure it up and create the insert.

  2. Design

    Our team lays out the insert for protection and easy access, then checks it before anything is cut.

  3. Cut

    CNC routers cut the foam to your layout, in the right material for the job.

  4. Deliver

    Quality-checked inserts dispatched Australia-wide, ready to drop into the case.

Start with your files Or call 03 9720 2550

Foam insert design & CAD

You don't need drawing files to start. Our team draws the insert in CAD, checks wall thicknesses and finger grips, then cuts it. Already have DXF or DWG files? We cut straight from those.

Start with any of these

  • DXF / DWG files
  • PDF or AI files
  • Photos with dimensions
  • A rough sketch
  • The gear itself

What we check before cutting

  • Max protection Padding laid out for heavy impacts
  • Finger grips Cutouts so every item lifts out easily
  • Space saving Items nested to make the most of the case
Send us what you have
Our design team models your equipment in CAD, so the fit is checked before cutting begins.

Foam material options

Six foams, from budget packaging to closed-cell protection for high-value gear. Not sure which suits yours? Tell us what goes in the case and we'll recommend one.

Ask which foam suits
  • Medium density PE45

    Max protection

    Medium density PE45

    Maximum protection for high-value items. Closed-cell, moisture resistant.

  • Mid-low density EPE

    Versatile

    Mid-low density EPE

    Lightweight and budget-friendly for bulk packaging and retail displays.

  • LD29 Plastazote

    Premium grade

    LD29 Plastazote

    Lightweight, tough and chemical resistant. Cross-linked closed-cell foam.

  • EVA

    Durable & smooth

    EVA

    Very resilient with a smooth finish. Suits heavy items and presentation cases.

  • Anti-static pink

    Electronics

    Anti-static pink

    Made to protect electronics from static discharge.

  • Eggcrate / serpentine

    Lid compression

    Eggcrate / serpentine

    Convoluted serpentine-cut foam for case lids. Compresses against your gear and holds it still in transit.

Custom coloured foam

From corporate colour matching to tool control, foam that carries your brand. Pick from our stock colours, layer two for a cut-through contrast, or ask about a custom colour on a bulk order.

Stock colours

Match my brand colours

Finishing options

  • Custom branding

    Screen printing of your logo or brand onto the foam insert. Minimum 10 units.

  • Poly toppers

    A rigid, wipeable polypropylene top layer for extra durability and a second colour.

  • Multi-layer

    Stacked layers and lift-out trays for dense kits and organised storage.

Foam insert applications

If it goes in a case, we can frame it in foam, from major industry programs to one-off custom projects.

  • Guitar sitting in a custom foam insert inside a flight case

    Touring & AV

    • Road and flight case inserts
    • Console inserts
    • Audio mixers
    • DJ controllers
    • Lighting moving heads
    • Microphone drawer inserts
    • Projector cases
  • VR headsets and controllers in custom foam inserts

    Camera & media

    • Cinema cameras
    • Camera lens kits
    • Gimbal inserts
    • VR/AR headsets
    • Broadcast gear
    • Drone flight cases
  • Industrial tool parts held in a custom foam insert

    Industrial & defence

    • Tool control (shadow boards)
    • Power tool kits
    • Survey equipment
    • Diagnostic equipment
    • Testing instruments
    • Robot and automation transport
    • Mining equipment
    • Defence gear
    • Aerospace
  • NSW Ambulance medical vials in a custom foam insert

    Medical & corporate

    • Medical device packaging
    • Laptop and tablet deployment
    • Hard drive transport
    • Server rack modules
    • Sample kits
    • Product launch kits
  • Compound bow and accessories in a custom foam insert

    Lifestyle & hobby

    • Sports and hunting equipment
    • Gun case foam
    • Wine bottle inserts
    • Collectibles and antiques

  • Don't see your item?

    We custom design for anything. Send a photo and the measurements and we'll draw the insert around it.

    Tell us what it is

What our clients say

  • “I got your case and it fit perfectly! Very well crafted. Thank you very much.”
    Alex stormsatsea
  • “Inserts are impressive.”
    Danesh Perera Director of Calibration and Technical Support, Pacific Sensor Technologies

Shipping Australia-wide

Manufactured in Bayswater, Melbourne. Custom foam inserts shipped to every state and territory, flat-packed and ready to drop straight into your case.

Dispatched from

Bayswater, VIC

  • Perth, WA
  • Sydney, NSW
  • Melbourne, VIC
  • Brisbane, QLD
  • Adelaide, SA
  • Canberra, ACT
  • Darwin, NT
  • Hobart, TAS

+ regional and remote areas

Frequently asked questions

Sizing, materials, lead times and delivery for custom foam inserts.

Can you match my existing case?

Yes. We work with Pelican, Storm, HPRC, SKB, Gator, and all major brands. Send your case model or dimensions.

Do you sell Pelican case foam inserts?

Both. We stock genuine Pelican-made replacement foam sets for popular case models, or we can custom CNC-cut and design a foam insert to fit your exact equipment in any Pelican, Storm or Air case.

Can you make custom foam inserts for a tool box?

Yes. Tool box foam inserts are one of our most popular jobs. We cut foam trays and shadow boards for tool chests, drawers and kits. See our tool chest custom foam inserts guide, or send your drawer dimensions for a quote.

What types of cases do you cut foam inserts for?

We cut foam inserts for hard cases, flight cases, Pelican cases, road cases, tool boxes, storage cases, gun cases, camera cases, and instrument cases. If it has an interior dimension, we can cut foam for it. Just send us the measurements or bring the case in.

What's the minimum order?

No minimum. Single prototypes to 500+ production units. Volume pricing available.

How much do custom foam inserts cost?

Price comes down to the sheet size, the foam type and density, how many layers the insert needs, and how many you want. A single-layer insert for one hard case sits at the low end. Multi-layer trays in premium closed-cell foam sit higher, and unit price drops on repeat runs. Send your case model or internal dimensions and a photo or list of the gear going in, and we'll quote the real number.

Do you cut serpentine or convoluted foam?

Yes. Serpentine foam (also called convoluted or eggcrate) is the usual choice for case lids, where it compresses onto your gear and stops it lifting in transit. We cut it to your case dimensions, either paired with a CNC-cut base insert or supplied on its own.

What is the custom foam cutting process?

We use CNC routers to cut foam to exact tolerances from your DXF/DWG files, photos, or direct measurements. Our engineers review every file before cutting. Turnaround varies depending on current workload. Contact us for lead times.

Do you ship foam inserts Australia-wide?

Yes. We manufacture in Bayswater, Melbourne and ship custom foam inserts to all Australian states and territories: Perth, Sydney, Brisbane, Adelaide, Darwin, and everywhere in between.

What file formats do you accept?

DXF, DWG, PDF, AI files. Or send photos with dimensions – we'll handle the CAD work.

Can you add my company logo?

Yes! Screen printing available for orders of 10+ units. Send your logo and we'll provide a mockup.

Do you offer colour matching?

We stock a wide range of foam colours. Custom colours available for bulk orders.

Didn't find your answer? Call 03 9720 2550 or ask in a quote request.

PROTECT WHAT MATTERS

Send your case model, internal dimensions or a photo of the gear. No minimum order and no obligation.

Start your foam quote Call 03 9720 2550