Don't let bad packaging break your gear.
Pick-and-pluck foam crumbles over time and loose bubble wrap shifts in transit. Our CNC router follows the outline of each item, so every piece sits in its own pocket and nothing moves around.
Designed by our in-house team and cut in Bayswater, Victoria.
Crumbles over time. Gear shifts in transit.
Shaped to your equipment. Nothing moves around.
If you have a case, we fit it.
Moulded cases, custom built crates, rack drawers, tubs and cartons. We template to your case, so the brand on the lid does not matter.
No case yet? We build custom road cases, flight cases and tool and equipment briefcases. As an authorised Pelican dealer we also supply Pelican cases, Pelican Spacecases and military and defence cases, and we can cut the insert for any of them.
The right foam for the job.
Three grades, each with a different balance of protection, finish and budget.
Not sure which? Send through the case and a photo of the items and we will spec the foam for you.
PE45 Closed-Cell
High density closed-cell polyethylene with a smooth CNC finish, chemically resistant. The first choice for Pelican cases and tool control.
- Water and oil proof
- Premium smooth finish
- Hard wearing
- Wipe-clean surface
Layered EPE Foam
Lightweight, cost-effective pearl foam. Suits high-volume packaging and occasional-travel cases where budget leads.
- Most economical option
- Lightweight
- Shock absorbent
- Recyclable material
Anti-Static Foam
Specialised ESD foam that stops static building up. The standard for circuit boards, avionics and lab electronics.
- ESD / static protection
- Pink identification
- Non-abrasive surface
- Static dissipative
Shadow foam, in your colours.
A contrasting base under the top layer. Pull a tool and its empty pocket shows up in colour, so a missing one is obvious at a glance.
We can print logos, part numbers or instructions onto the top layer. Useful for branding, retail packaging and inventory control.
Who we cut foam for.
Six industries, one real job from each.
Bike NowCustom Foam Tool Insert Multi Layered
Multi layered foam tool insert for Bike Now. Tools sit across several levels, finished with a polypropylene topper.
View this job
Australian Federal Police (AFP)Pelican Custom Foam Insert Pistol Case
Pelican foam insert cut as a pistol case for the Australian Federal Police, finished with a polypropylene topper.
View this job
Custom Pelican Case Insert With Anti Static Foam
Pelican insert cut from anti-static foam, so sensitive electronics travel without picking up a static charge.
View this job
Arts Centre MelbourneCustom Foam Drawers Inserts For Microphones & Audio Equipment
Foam drawer inserts for Arts Centre Melbourne, cut to hold microphones and audio gear under a polypropylene topper.
View this job
Sydney Essential Oils CompanySales Display Briefcase With Custom Foam Insert and Screen Printing
Sales display briefcase for Sydney Essential Oils Company, with a removable tray and screen printed branding.
View this job
Advanced Skin TechnologiesPearl Foam Custom Foam Insert For Product Packaging
Pearl foam packaging insert for Advanced Skin Technologies, cut to hold each product in place through retail transit.
View this jobGot gear like this? Send the case and a photo of the items and we will quote the insert.
Get a QuoteRecent foam projects
More inserts from the workshop. Tap a photo to view it full size.
Getting a quote.
Two ways to design the layout. Either way, the quote starts with the same few details.
Full Service Design
Bring your gear into the showroom, post your items to us, or send photos and sketches. Our design team measures the items and creates the layout for you.
DIY Design (Your File)
Already have a DXF or CAD file? Send it over and we cut straight from your design, to your spec.
To quote, we need
- The inside size of your case, drawer or box
- Photos of the items it needs to hold
- Your DXF, if you already have a layout
CNC cut in Bayswater, VICFrequently asked.
Materials, fit, colours and samples. The questions that come up before you commit.
What brands of cases do you fit?
We cut to the case, so the brand is not a limit. That covers Pelican and Pelican Storm, Trimcast Spacecase, Nanuk, SKB, Explorer and MAX, along with custom timber road cases, aluminium flight cases, 19" rack drawers, plastic stacking tubs and cardboard cartons.
Do I need to send my equipment to you?
Not always. For simple shapes, measurements and photos are enough. For the most accurate fit you can bring items into the Bayswater showroom or post them to us. We can also work from technical drawings or your own DXF design.
What industries do you cut foam inserts for?
Tool control is the biggest one: a pocket per tool in a Pelican case for on-site service kits, or in a workshop drawer system, so a missing tool is obvious at a glance and nothing moves in transit. We also cut technical packaging for government and defence equipment, test and communications gear, weapons and training kits, sales demo and display cases, sensitive electronics on anti-static foam, AV and audio kit, and product packaging from small local batches up to mass production runs.
Can you replace the pick and pluck foam in my case?
Yes. Swapping tired pick and pluck for a custom cut insert is the same job as a new fit-out, and because we cut to the case the model is not a limit. Recent examples include Pelican 1510, 1535, 1550, 1607, 1637 and iM series cases, plus Storm, Trimcast Spacecase, Nanuk, SKB, Explorer and MAX.
Is shadow foam the same as kaizen foam?
Same idea, different name. Shadow foam, kaizen foam and tool control foam all describe a layered insert where every tool sits in its own cut pocket, usually over a contrasting colour so an empty pocket stands out. We cut it for Pelican cases, toolbox and chest drawers, and workshop trolleys.
Can I get custom colours or printing?
Yes. Foam and top layer colours include black, red, pink, orange, green, blue and yellow, which is what makes shadow foaming for tool control work. Top layer printing is available for logos, part numbers or instructions.
What thicknesses are available?
We stock a range of foam thicknesses from 5mm up to 60mm, and layers can be laminated to reach the depth your case needs.
What does a custom foam insert cost?
It comes down to the foam grade, the size of the case and how many layers the layout needs. EPE pearl foam is the most economical, PE45 sits above it, and anti-static is the specialist option. Send through the case and a photo of the items and we will quote the insert.
Do you cut one-off inserts, or only production runs?
Both. Single inserts, small local runs and full production quantities are cut on the same CNC machines, so a one-off tool tray and a packaging run go through the same process.
Ready to protect your equipment?
Send through your case and equipment details and we will spec the foam, layout and finish. Free quote, no obligation.
Get a Quote- Quote within 24 hours
- Free, no-obligation
- Australian made