Don't let bad packaging break your gear.
Pick-and-pluck foam crumbles over time and loose bubble wrap shifts in transit. Our CNC cut inserts are shaped to your actual equipment, so nothing moves around. Designed and cut in Bayswater, Victoria.
Pelican, Storm, Spacecase, Nanuk, SKB, Explorer and MAX, plus road cases, timber crates, rack drawers and cartons. If you have a case, we cut foam for it.
Advanced routing follows the contours of your equipment. No crumbling pick-and-pluck, no bubble wrap shifting around in transit.
Bring your gear into the Bayswater showroom, post it to us, or send a DXF. We measure, design and cut the layout for you.
The right foam for the job.
Three grades, each with a different balance of protection, finish and budget.
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
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 those too: Pelican cases, Trimcast Spacecases, custom road cases, tool briefcases and equipment cases and military and defence cases, each with an insert cut to suit.
From the battlefield to the boardroom.
Custom Foam Tool Insert Multi Layered
Pelican Custom Foam Insert Pistol Case
Custom Pelican Case Insert With Anti Static Foam
Custom Foam Drawers Inserts For Microphones & Audio Equipment
Sales Display Briefcase With Custom Foam Insert and Screen Printing
Pearl Foam Custom Foam Insert For Product Packaging
LEAN Tool Control
Every tool has a place, and a missing one is obvious at a glance.
Government & Defence
Technical packaging for equipment that has to work on arrival.
Sensitive Electronics
ESD foam for boards and instruments that static can kill.
AV, Audio & Field Kit
Gear that travels every week and has to work on landing.
Sales Demo Kits
A travelling kit that opens well in front of a client.
Product Packaging
Small local runs through to mass production.
Colours and printing.
Shadow Foaming Colours
Pick your foam colour and, where applicable, a contrasting top layer for instant tool identification.
Top Layer Printing
We can print logos, part numbers or instructions onto the top layer. Useful for branding, retail packaging and inventory control.
Two ways to design.
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.
Our process.
For quoting we need the general sizing of the case or receptacle, plus some images of the items you need to house.
Measure
We size your case or receptacle and the items going in it. Photos help, or send your own DXF.
Design
Our design team draws the layout, or we cut from your file if you have one.
CNC Cut
Precision routing in your chosen foam, thickness and colour.
Protect
Your insert arrives ready to drop into the case and use.
Recent foam projects.
Custom inserts we have designed and cut. Tap any image to view full resolution.
Frequently 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. Call (03) 9720 5300 or email sales@protectapack.com.au with your case details.
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.
- Quote within 24 hours
- Free, no-obligation
- Australian made