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Engineer inspecting a 3D-printed part with calipers.

How to customize foam in a Pelican™ case

How to customize foam in a Pelican™ case:

At Custom Case Pros, we noticed there are several names used for referencing foam: foam insert, foam cushion, foam dunnage, base foam, lid foam…the list goes on. And, if we told you the secret, to customizing foam, we’d have to kill you. Totally kidding! There is a science to it that we have mastered, which hinges on the custom foam design and execution of its production. We work directly with our clients to develop the foam drawing package so that you can visualize exactly what you’re getting before we build it. We want you to be happy with the layout and understand how your parts will fit into the foam cushion before we build.

Depending on the fabrication method required by the design and the foam materials being used, we determine what equipment will be used for your product. Foam fabrication involves different types of machinery, including water-jet, die-press, CNC router, profile cutter, table saw and many more. Since these machines operate differently and each one offers certain advantages and disadvantages, the specific machine used for your project will be determined using a number of factors, including foam type (i.e. polyethylene, polyurethane, cross-link), foam density, design complexity, customer location, etc. The drawing files are drafted to seamlessly send instructions to the appropriate machine before our shop personnel completes the fabrication and assembly. Our quality standards and inspections ensure accurate fabrication every time. Inevitably, mistakes occasionally happen and if they do, we’ll work with you to send a replacement as quickly as possible.

If your foam insert is ordered with a case, we’ll install it to ensure the perfect fit. We account for the internal case features and engineering aspects upon installation, so that you don’t have to. Some Pelican ™ cases have unique shapes, internal features, and draft angles, all of which require adjustment to the foam cushion for proper case installation.


Figure 1: (Pelican ™ 1630)

Figure 1: (Pelican ™ 1630)


Figure 2: (Pelican ™ 1470)


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