FILES
Send us your DXF or DWG outline files, your desired layout, or cut-ready CAD files to work from.
Australia's custom foam insert specialists. Precision CNC-cut foam that transforms generic cases into bespoke protection systems — designed and made in Melbourne, shipped Australia-wide.
Universal Compatibility
Supply your own case or pair with one of ours — we cut custom foam inserts Australia-wide for any brand, any model, any size. Pelican, Storm, Nanuk, SKB and more. Need a full transport solution? See our Custom Road Cases.
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
CNC Precision
We cut hard case foam inserts, flight case foam inserts, and storage case foam to exact tolerances using CNC routers — no gaps, no movement, no damage. Kitting out a tool chest? See our guide to tool box foam inserts.
Any Dimension
Fits any internal case size
Case or Specs
Send the case or just measurements
All Densities
Budget EPE to premium closed-cell
Fast Turnaround
Contact us for current lead times
Pelican Case Foam
Whether you need genuine Pelican-made foam or a fully custom design, we cover every Pelican, Storm and Air case model.
Factory replacement foam sets made by Pelican for your exact model — ready to drop straight in.
Shop Replacement Foam →CNC-cut and CAD-designed to your gear — perfect cavities, clean edges, holds kit dead-still in transit.
Get Custom Quote →Workflow
We've streamlined our production to get your gear protected faster.
Send us your DXF or DWG outline files, your desired layout, or cut-ready CAD files to work from.
Don't have access to design files? Just bring in your equipment and let us do the rest – we can measure-up and create your perfect insert.
Engineers create layouts optimized for protection and accessibility.
Precision CNC technology creates premium foam inserts using the best material for the job.
Quality-checked inserts dispatched Australia-wide, ready for the road.
Precision
Our expert design team uses state-of-the-art CAD software to create 3D models of your equipment, ensuring a perfect fit before cutting begins.
Optimized padding for heavy impacts
Ergonomic cutouts for easy access
Smart nesting to maximize volume
Why Precision Matters
Material Selection
Maximum protection for high-value items. Closed-cell, moisture resistant.
Lightweight & budget-friendly for bulk packaging and retail displays.
Lightweight, tough, and chemical resistant. Superior cross-linked closed cell foam.
Extremely resilient with a premium smooth finish. Perfect for heavy items and presentation.
Engineered to safeguard electronics from static discharge.
Convoluted foam ideal for case lids, gently compressing and holding gear securely in place.
Customization
From corporate colour matching to equipment management - foam that reflects your brand identity.
Professional screen printing of your logo or or brand onto foam inserts (Min. 10 orders).
Add a rigid, wipeable polypropylene layer for enhanced durability and distinct color branding.
Complex stacking solutions for maximum density and organized storage.
Versatility
If it goes in a case, we can frame it in foam. We serve major industries with certified protection standards and cater to unique custom projects of any scale.
Cinema Cameras • VR Headsets • Broadcast Gear
Mining Tools • Defense Gear • Aerospace
Don't see your specific item? We custom design for anything.
Our Clients
Customer Feedback
"I got your case and it fit perfectly! Very well crafted. Thank you very much."
Alex
stormsatsea
"Inserts are impressive."
Nationwide Service
Manufactured in Bayswater, Melbourne. Custom foam inserts for cases shipped to every state and territory — fast, flat-packed and ready to drop straight into your case.
Common Questions
Yes. We work with Pelican, Storm, HPRC, SKB, Gator, and all major brands. Send your case model or dimensions.
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.
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.
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.
No minimum. Single prototypes to 500+ production units. Volume pricing available.
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.
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.
DXF, DWG, PDF, AI files. Or send photos with dimensions – we'll handle the CAD work.
Yes! Screen printing available for orders of 10+ units. Send your logo and we'll provide a mockup.
We stock a wide range of foam colours. Custom colours available for bulk orders.
Get a bespoke foam insert quote. Made in Australia, engineered for life.
