Custom Corner: Exploring Foam Cushioning Systems for Pelican Cases

In our previous blog post, Custom Corner: Understanding Foam Materials For Custom Case Designs, we explored the various types of foams—polyurethane, polyethylene, and more—that provide critical protection for sensitive equipment. Today, we’re taking that knowledge a step further by diving into the custom foam cushioning systems we offer for Pelican cases. Whether you need extra durability, precision-fit cavities, or removable trays for versatile storage, this post will guide you through the options to help ensure your gear stays safe and secure during transport. Let’s take a closer look at how you can tailor your Pelican case with the right foam design.

At Custom Case Pros, we offer a wide range of foam cushioning systems for Pelican cases, designed to protect your equipment. Understanding the foam materials and configuration options is key to ensuring optimal protection, whether you’re transporting delicate electronics or heavier equipment. Let’s break down the cushioning systems available for your custom cases.

 

Materials

We use two main types of foam in our Pelican cases, each chosen for its unique properties:

• Polyethylene (PE) Foam (2 Pounds/Cubic Foot): PE foam is a firm, closed-cell material that offers excellent durability. It’s ideal for heavier equipment like communications devices, power supplies, or other general-use applications. PE foam supports a load range of 0.20 to 1.0 pounds per square inch, providing superior protection for items that need more robust support. (Density: 32 kg/m3)

• Polyurethane (PU) Foam (1.8 Pounds/Cubic Foot): PU foam is a softer, open-cell foam best suited for lighter, more fragile items. It provides more cushioning for sensitive equipment like monitors or other delicate tools, and its load range is 0.08 to 0.40 pounds per square inch. (Density: 30 kg/m3)

Additionally, both foam types come in anti-static versions, which help reduce static electricity buildup—a key factor when transporting electronic components.

 

Types of Cushioning Systems

Our Pelican cases can be customized with different foam configurations to suit your equipment’s specific needs:

• Foam Filled: In foam-filled cases, multiple layers of foam are combined, offering versatility for items with varying protection needs. These layers typically come in 1-inch or 2-inch thicknesses, allowing you to customize the foam’s density and structure for optimal cushioning. This option does require your handy work, if you intend to create your own custom foam cavities.

• Foam Lined: This option lines the interior of your Pelican case with a uniform foam layer, typically 1 or 2 inches thick. This is ideal for items that require a more consistent layer of protection throughout the case and can be a very economical option when individual foam cavities are not required.

• Custom Cushion: Need a tailored solution? At Custom Case Pros, our design team can work from your sketches, equipment drawings or physical parts to create custom foam inserts with multiple cavities, perfectly suited to your exact specifications. In certain situations, we may provide hands-on measuring at your facility. Give us a call to discuss the option that works best for you!

 

Custom Cushioning Options: Your Sketch

We value your input in the design process. By sending us a sketch of your item or the desired layout for your case, we can ensure complete control over cavity sizes and exact placements. Whether you send a rough drawing or detailed equipment specs, our designers will work with you to craft a solution that offers the best protection possible.

If you’re unsure about what you need, or don’t have part drawings or detailed equipment specifications, don’t worry! Our team is here to guide you through the process. By asking the right questions and learning about your challenges and goals, we can design a custom solution that perfectly fits your requirements. Whether it’s understanding the fragility of your equipment or identifying key storage needs, we’re committed to helping you find the ideal cushioning system.

 

Additional Cushioning System Options

At Custom Case Pros, we offer a variety of extra features for Pelican cases that provide further protection and organization for your gear:

• Partitions: These load spreaders/dividers are made from high-density polyethylene (HDPE), which is glued into the foam to separate compartments. This prevents heavier items from damaging fragile equipment in adjacent sections of the case.

• Velcro Straps: Velcro straps can be added to secure loose items such as coiled cables or other accessories inside the lid compartments, ensuring everything stays in place during transport.

• Removable Foam Trays: For added versatility, we offer removable foam trays that can be customized for any part or equipment. These trays often come with reinforced HDPE bottoms to provide added support and stability. For easy handling, straps can be attached to the trays, or hand cutouts can be integrated into the foam for quick and convenient removal. This option is perfect for cases that need to store and transport parts in multiple layers, providing flexibility while maintaining durability.

 

With our range of materials and customization options, we can help you create the perfect foam cushioning system to protect your equipment. Whether you need extra durability or a soft touch for delicate tools, our team will work closely with you to design a solution that meets your specific needs. Get in touch with us today to start designing your custom Pelican case and foam solution!

info@customcasepros.com

(405) 566-9290