We manufacture precision-cut foam inserts tailored exactly to your equipment, ensuring a secure fit and a professional finish. Every insert is cut in-house in the UK, in a range of densities, thicknesses and layer combinations, including anti-static and medical grade foam.
Whether you need an insert for a case we built, a case you already own, or a shipping box, we work from your equipment rather than a template.
Get a Custom Foam Insert Quote →
Why Foam Matters More Than the Case Shell
A flight case shell does one job: it stops crushing, punctures, and the worst of an impact. Foam does the rest. It absorbs shock before it reaches your equipment, stops items moving and knocking against each other in transit, and spreads pressure evenly across a surface instead of letting it concentrate on one point, which is exactly how screens, lenses, and delicate electronics get cracked.
This is why two cases can look identical from the outside and perform completely differently in practice. The foam layout — not just the material, but how it is cut and positioned — is doing most of the protective work.
What We Offer
- Fully custom foam layouts based on your equipment
- CNC-cut and laser-cut foam for high accuracy
- Single-layer or multi-layer foam designs
- Lift-out sections and layered protection systems
- Laser cutting and engraving
- Inserts for cases and boxes not manufactured by us
- Re-foaming and replacement inserts for existing cases
Inserts are commonly supplied in black or grey, with other colours available, and can be cut to any thickness or layer combination your equipment requires.
Foam Types and When to Use Them
High-density closed-cell foam
Denser and firmer, closed-cell foam does not absorb moisture and holds its shape under repeated compression, which makes it the better choice for heavier equipment or cases that get packed and unpacked constantly. It is commonly used for cameras, broadcast equipment, and anything where the foam needs to keep its exact profile trip after trip.
Medium density foam
General-purpose protection, suitable for the majority of equipment where the load is moderate and the case is handled regularly rather than daily.
Soft and open-cell foam
Softer and more absorbent, open-cell foam is often used as a top or base layer for cushioning rather than structural support, and for protecting delicate surfaces and finishes. It is a good complement to a firmer foam base but is not usually the right choice on its own for heavier or high-value items.
Anti-static foam
For sensitive electronics — circuit boards, servers, broadcast components — anti-static foam prevents electrostatic discharge from damaging components during handling and transit. Worth specifying whenever a case is carrying anything with exposed circuitry.
Medical grade foam
Used where cleanliness and consistency matter, for diagnostic instruments, laboratory equipment and other precision medical tools.
Convoluted (pick-and-pluck) foam
This is the foam with the egg-box texture, pre-scored into small cubes you pluck out by hand to create a cavity for each item. It is flexible and low-cost, and works for irregularly shaped tools, cables, and accessories where you need quick, adjustable protection rather than a precision fit. However, it can lose its shape and deteriorate relatively quickly, particularly with repeated use. What seems cheaper initially may mean replacing the foam sooner and paying twice.
For long-term protection, we recommend precision CNC-cut foam, designed to fit your equipment correctly from the start.
Custom-Cut Inserts vs Standard Padding
Standard padding — foam sheets or generic pick-and-pluck blocks — works fine for equipment that is not especially delicate, expensive, or oddly shaped. It is the cheaper option and it is fast to fit.
Custom-cut foam inserts are precision-cut to the exact profile of your equipment, so every item sits in its own cavity with zero movement. This matters most when:
- The equipment is high-value or difficult to replace
- You are transporting multiple items that need to stay separated and organised
- The gear has an irregular shape that generic foam cannot properly support
- The case will be opened and repacked frequently, and consistent positioning speeds up that process
- You need a professional, branded interior — common for broadcast, medical, and touring equipment
The trade-off is straightforward: custom foam costs more up front because it is made specifically for your equipment, but it reduces the risk of damage, replacement costs, and downtime, which usually makes it the cheaper option over the life of the case.
How Foam Thickness and Density Are Chosen
There is no single right foam — it depends on the equipment. As a general approach:
- Fragile or delicate items (camera lenses, screens, glass components) need a lower-density foam that compresses slightly to absorb shock, paired with a firm surrounding structure to stop movement.
- Heavy equipment (amplifiers, rack units, motorsport parts) needs high-density foam that will not compress or wear down under repeated weight.
- Mixed loads often use layered foam — a firmer base for structural support with a softer top layer for cushioning.
Getting the density wrong in either direction either fails to protect the equipment or fails to hold its shape after a few uses. This is where working with a manufacturer rather than buying generic foam pays off.
Industries We Supply
- Broadcast and film — cameras, lenses, monitors, audio gear
- Music and live events — mixing consoles, wireless systems, DJ equipment
- Medical and scientific — diagnostic instruments, laboratory equipment
- Industrial and engineering — tools, prototypes, calibration equipment
- Defence and security — communications equipment, drone systems
- Shooting and sporting — precision-cut inserts under our RFD service
How We Make Your Foam Inserts
- Send us your equipment details. Measurements, photos, or the make and model. If you are unsure what we need, see our measuring guide.
- We design the layout. We look at the weight, shape, value, and how often the case will be opened and repacked, then design the foam layout around that.
- We cut and supply. CNC and laser cutting in-house, fitted to your case or supplied loose.
Frequently Asked Questions
Can you make foam inserts for a case you did not manufacture?
Yes. We regularly cut inserts for cases and boxes bought elsewhere, including off-the-shelf hard cases and shipping containers. We need the internal dimensions of the case as well as the equipment details.
Can you re-foam an existing case?
Yes. Re-foaming is part of our repair and modification service and is often more cost-effective than replacing a case that is structurally sound.
What do you need from me to quote?
The equipment dimensions in millimetres, the internal dimensions of the case if you already have one, and a note on how the case will be used and transported. Photos help, particularly for irregular shapes.
What thickness of foam do I need?
It depends on the weight and fragility of the equipment and how the case will be handled. Tell us what you are protecting and we will recommend a thickness and density as part of your quote.
Do you supply foam without a case?
Yes. We supply cut foam inserts, sheets and layered sets on their own.
Get a Foam Insert Quote
Every insert we make starts with the equipment, not a template. Send us the details of what you are transporting and we will recommend a foam layout as part of your free, no-obligation quote.