Custom Foam Inserts

Custom foam inserts are an optional extra for the inside of your Peli Case. They are manufactured to fit the precise shape of your equipment giving your case a great look and maximum protection.

peli storm custom foam

Why do cases need foam?

Foam plays a pivotal role in protecting the contents of your case. A foam interior gives your equipment the cushioned protection it needs while in transit and helps to protect your items against shock and vibration as well as unexpected mishandling. It can be utilised in the main body of the case as well as inside the case lid so that your equipment is surrounded by foam in all directions.

What is standard foam?

The majority of Peli Cases and Storm Cases can be purchased pre-installed with foam. These are standard foam inserts manufactured by Peli, often Pick N Pluck™ foam. (To read more about standard case foam, click here.)

Why choose custom foam?

Custom foam is different. It's a bespoke option that provides a higher level of protection for your equipment than standard Pick N Pluck foam. It also offers a more attractive appearance which is useful if you are looking to make a strong impression.


Custom foam is particularly useful for cushioning intricate parts and high value equipment. When you order custom foam, we design and manufacture a foam insert that is tailored specifically to your needs. First and foremost of course that means we create cavities that fit the precise shape of your equipment. But it doesn't end there; we also take into account other factors such as your product's weight, its fragility, functionality and the ease of packing or demonstrating.

custom foam in a Peli case


In addition to its superior protective qualities, a custom foam insert means we can do more with the way your equipment is presented too. For instance, different coloured laminated foams allow you to extend your brand identity from the outside of the case to the inside. A particularly nice effect is colour contrasting which involves using one colour for the top few millimeters of foam and a different colour for the cavities. Known as shadow foam, it lets you see at a glance whether an item is missing - invaluable if your case is going to hold multiple tools and instruments. We can also laser etch into the foam or adhere a printed panel. This is a great way to enhance your brand, especially when combined with graphics on the case itself.

How are measurements obtained?

Where possible, we like to receive your products or exact replicas so that we have physical objects to work from when designing and manufacturing the case interior for your Peli Case. However we fully understand that this is not always possible for everyone which is why we also accept CAD files. If you are sending us CAD files, do remember that mistakes in your CAD files can end up costly, so we expect you to take full responsibility for the accuracy of all files that you send us.

custom case foam

How do we do this?

We use the latest state of the art technology to cut the foam to an exceptionally high accuracy so that it is just right for your equipment. We achieve this by using CNC, water jet cutting and die cut shaping to engineer foam interiors designed to offer maximum protection for your tools and equipment. We use AutoCAD® and SolidWorks® and have FARO® scanning facilities for any intricate items that require the 3D touch.

Peli case custom foam

Interested? Get in touch.

To get started, call us on 01275 866 366 Mon-Fri or click here for a free no-obligation quote.

Don't worry, we aren't into hard selling! We'll just explain your options and advise what we think is going to be best for your needs. For example, it may be that your product is going to require anti-static foam or clean environment nylon. We have many years' experience in designing and manufacturing case interiors - we know cases inside and out. Our costs for bespoke foam inserts are competitive so why not speak to one of our experienced team and we'd be happy to talk through your options.

Got a question?

Feel free to ask us in the form below:

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or Call us 01275 866 366 M-F 9am-5pm

Choose Cases UK and get:

  • Highly accurate and precise shaped foam
  • Carefully calculated levels of protection
  • Choice of different colours
  • Branding options
  • Fast efficient service
  • Highly experienced team
  • Excellent customer support

Let us create the best fit for your equipment!

Peli custom foam

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tool case foam