Custom Foam Inserts For Cases
Custom foam inserts are essential for protecting valuable equipment from impacts, drops, and vibration. While a quality protective case shields from external elements, it's the precision-cut foam interior that provides the critical cushioning and organization your equipment needs.
At Production Case, we combine over 30 years of technical expertise with advanced manufacturing capabilities to create premium custom foam solutions. Our in-house Canadian facility handles everything from design through manufacturing, ensuring exceptional quality control and quick turnaround times.
Our Custom Foam Process
Our in-house design and manufacturing team can create precise custom foam interiors and inserts for almost any brand or use. We can also use your design files to make them exactly how you need them.
Whether you need it for a Pelican, Nanuk, SKB or custom case, Production Case has you covered!
From a single custom foam insert to runs of hundreds, we’ll deliver what you need.
Our process for designing and creating your custom foam includes:
1. Our Expert Consultation
- In-person or virtual evaluation of your equipment
- Assessment to meet superior protection requirements
- Discussion of usage environment and conditions
- Material and design recommendations
2. Precision Foam Design
- CAD modelling for a snug fit
- Optimization for maximum protection
- Client review and approval
- Manufacturing specifications preparation
3. Canadian Quality Manufacturing
- Premium material selection
- CNC precision cutting
- Rigorous quality inspection
- Secure handling throughout
4. Final Inspection & Delivery
- Comprehensive quality check
- Fit testing with equipment (when possible)
- Secure packaging
- Delivery coordination
We operate a fully equipped, Canadian-based facility, giving us complete control over the design, cutting, and assessment process. Our in-house design and manufacturing mean we can meet tight deadlines and deliver exceptional craftsmanship.
WHY INVEST IN A CUSTOM FOAM INSERT?
We can manufacture your custom inserts using the best type of foam for your case. The options we use include:
Cross-Linked Polyethylene (XLPE)
- Our premium dense foam choice
- Superior impact protection
- Professional finish
- Ideal for high-value equipment
- Excellent chemical resistance
- Perfect for long-term protection
Convoluted Polyurethane
- Even pressure foam distribution
- Perfect for case lids
- Additional shock protection
- Customizable density
- Ideal for fragile equipment
Polyethylene
- Firm and durable
- Water-resistant properties
- Great for heavier equipment
- Cost-effective protection
- Ideal for tools and firearms
Polyurethane
- Soft cushioning properties
- Perfect for delicate electronics
- Excellent shock absorption
- Cost-effective solution
- Ideal for lighter items
The best foam to use depends on what you need to protect, and your budget. The weight and value of the equipment you’re protecting inside the case can help you decide, and our experts can also help you make a decision.
Industries We Serve
Our custom foam solutions protect critical equipment across numerous sectors:
Military & Defense
- In-person or virtual evaluation of your equipment
- Assessment to meet superior protection requirements
- Discussion of usage environment and conditions
- Material and design recommendations
Military & Defense
- CAD modelling for a snug fit
- Optimization for maximum protection
- Client review and approval
- Manufacturing specifications preparation
Entertainment & Performance
- Premium material selection
- CNC precision cutting
- Rigorous quality inspection
- Secure handling throughout
Industrial & Professional
- Comprehensive quality check
- Fit testing with equipment (when possible)
- Secure packaging
- Delivery coordination
The Production Case Advantage
- Precision design and manufacturing
- Advanced cutting techniques
- Premium material selection
- Comprehensive quality assurance
- Extended equipment life
- Professional organization
- Reliable protection
- Investment preservation
- Technical consultation
- Material selection guidance
- Design optimization
- Ongoing support
Why Choose Custom Foam Inserts?
Custom foam inserts protect your valuable equipment from jostles, drops, and shocks by keeping it snug and securely in place.
A solid protective case will shield your gear and protect it from the elements, but it’s the foam inserts and interior that will hold each piece and soften impacts.
At Production Case, we use precision design and machining along with high-end materials to create the most protective foam inserts possible. Our custom foam inserts will organize, cradle, and protect your delicate gear against impact, vibration, and moisture.
- Complete in-house design and manufacturing in Ottawa
- Premium materials sourced from Canadian suppliers
- Rigorous quality control at every step
- Quick turnaround capabilities for urgent needs
- Advanced 3D scanning capabilities for precise measurements
- CAD expertise to optimize and enhance technical drawings
- 3D printing for prototypes and testing
- State-of-the-art CNC precision cutting
- Secure facility with controlled access
- Experience with classified and sensitive projects
- Track record with military and government clients
- Strict confidentiality protocols
Get a Quote Today
With years of experience delivering custom cut foam inserts to different industries and our own in-house production and design team, Production Case is your best choice for custom foam case interiors and inserts.
Request a personalized quote and find out how we can work together to protect your valuable equipment inside any off-the-shelf or custom case.
How to Cut Your Own Custom Foam Inserts
Production Case's in-house CAD/CAM expertise and CNC (computer numerical control) foam cutting equipment allow us to cut incredibly intricate and complex pockets to protect our clients’ sensitive case equipment. We are often challenged to produce custom foam cases that will ultimately protect many thousands of dollars’ worth of equipment.
But the average person like you and me may not be able to afford to absorb the one-time engineering costs to produce a CNC cut foam piece for one or two cases. That doesn’t mean we are left without options: with a reasonable amount of manual dexterity and some time, you can create your own custom foam case inserts.
