Protectapack Logo

Custom Foam Inserts

Technical Packaging & CNC Foam Inserts

cnc machine cutting foam insert

The Technical Packaging Experts

We are the technical packaging experts, using CNC foam cutting technology and an experienced design team on the go, we can find a technical protective packaging solution to suit your application!

Custom Foam Inserts To Fit All Budgets & Requirements

From low cost, bulk product packaging to suit your range of products, one off runs, to lean manufacturing tool accountability and protection, we cater for the lot.

Case foam cutting is our specialty and we are eager to provide you with the highest quality product.


With a range of different foams available, ranging from low use, budget options, through to high quality closed cell foams and anti-static variants, anything is possible.

We can CNC foam to any specs that you may have to ensure you have a custom solution that fits your need.


We can produce foam inserts for our range of custom protective cases like our Road cases and Flight cases, custom Pelican case foam inserts, custom tool case/drawer inserts, 19″ rack drawer foam inserts, storage tub foam inserts, custom CNC foam fit outs for many other brands of protective cases.

Pelican case custom foam inserts are a great way to protect your equipment to the highest standard.

Custom Foam Inserts to Suit
  • A variety of foam types and thicknesses available
  • Pick your foam colour and your top layer colour (where applicable)
  • Top layer printing available
  • DIY design, or we can do it for you!
Our Process

Our process is straightforward, for quoting purposes, general sizing of the case/receptacle (or actual item) is needed, plus some images of the items you need to house.

We can work off technical drawings, your own DXF design, or bring/send your items to us for a no-fuss, perfect fitting insert, we can even send you an initial cut for your reference to make sure you are as happy as we are with the final outcome, before completing the rest of the order.

Custom Foam Inserts Gallery

By Industry

LEAN Tool Control and Accountability

Custom cut foam inserts are a great way to keep your tool kits organised and all your expensive tools accounted for, whether its it’s a mobile pelican case for on site service kits, or drawer systems for workshop/manufacturing facilities, this is the best way to ensure all tools find their way home! Tool box foam inserts ensure that your tools will sit neatly in position when you transport them, reducing the risk of damage.

Sales Demo Kits

A great tailored solution to your traveling demo or sales kit, pack a variety of demo items into a custom cut foam case for a professional look and ultimate protection for your travelling kit. Our foam cut-outs can be made with a range of foam grades according to your budget and needs.

Government and Defence

Properly packaged equipment is the first step in getting the job at hand done, we offer technical packaging for any manner of equipment, from test equipment, communications gear, machinery and vehicle parts to weapons, training kits and other defence equipment. Combined with a Pelican, Trimcast or road/flight case, we can work with you to find the perfect solution.

Custom Product Packaging

A great professional idea for bulk product packaging, a variety of colourful foam and top layers available, whether it be a small run for low volume locally made product, or large runs for mass production, we can custom cut foam for all applications!