Custom Foam Inserts for Cases
Precision-engineered interiors designed to prevent damage, improve efficiency, and perform in the real world.
Trusted by dozens of Fortune 500 corporations, and the U.S. Military
Why Custom is Crucial For Foam Inserts
The strongest exterior is nothing without a secure interior. Instead of relying on generic inserts, custom foam is engineered around your specific equipment, improving protection, organization, and day-to-day efficiency in the field.
PROFESSIONAL PROTECTION
Each insert is designed with the right foam density and compression to properly support and protect your exact components.
professional organization
Clean, intentional layouts make it easy to see what belongs where—reducing setup time and keeping teams focused.
long-term reliability
Engineered to maintain shape and performance over time, delivering consistent protection through repeated use.
CUSTOM FOAM INSERT CAPABILITIES
Effective foam design goes beyond simply cutting shapes into material. The right combination of foam type, configuration, finish, and fabrication method directly impacts protection, organization, usability, and long-term durability. At C.H. Ellis, we consider how every aspect of your case will need to operate in the real world.
FOAM MATERIALS
The right foam material depends on your equipment, environment, and protection requirements. C.H. Ellis helps match the right foam type to your specific application for long-term performance and reliability.
Styles & Configurations
Different applications require different approaches to organization, visibility, and protection. We offer a wide range of foam styles and configurations to fit your workflow.
Foam Finishes & Customization
FOAM MATERIALS
The right fabrication process depends on your foam material, tolerances, and production requirements.
Behavior-Driven Foam Design From Start to Finish
At C.H. Ellis, custom foam inserts are designed around more than just dimensions. We take a behavior-driven approach where we consider how your equipment is transported, handled, accessed, and used in the real world to create interiors that improve both protection and usability.
DISCOVERY & APPLICATION REVIEW
We start by learning about your equipment, environment, workflow, and protection requirements. Whether you have detailed specifications or just an idea, our team helps define the right path forward.
Design & Engineering
Using CAD modeling and decades of experience, we develop foam layouts engineered around your specific equipment and how your team actually interacts with it in the field.
Material & Fabrication Selection
We match the right foam materials, densities, finishes, and fabrication methods, including CNC routing, waterjet cutting, and die cutting, to your application, budget, and production needs.
Sampling & Iteration
Pre-production samples and first articles allow you to validate fit, function, and appearance before full production. Need adjustments? We refine the design until it’s right.
Production & Delivery
With over 120 years of manufacturing experience, our team delivers high-quality foam inserts built for long-term performance, consistency, and real-world durability.
Industries We Support
Custom foam inserts for aerospace tools, calibration devices, and mission-critical equipment requiring protection, organization, and FOD control during transport and field use.
Aerospace
Protect sensitive diagnostic and medical equipment with custom foam cases engineered for precision fit, clean organization, and reliable transport.
Medical Devices
Improve efficiency for mobile technicians with foam inserts designed for fast tool access, equipment accountability, and rugged field conditions.
Field Service & Utilities
Custom foam solutions for industrial tools, gauges, and equipment that reduce movement, improve organization, and support long-term durability.
Industrial & Manufacturing
Anti-static foam inserts designed to protect sensitive electronics, testing equipment, and technical devices from impact and static discharge
Electronics & Technology
Precision foam inserts for calibration tools and measurement devices that require secure positioning, repeatable organization, and protection during transport.
Calibration & Measurement Equipment
Precision hard cases for calibration tools and measurement devices that require repeatable organization, secure positioning, and dependable protection in transit.
Defense
alternatives to custom foam inserts
Custom foam inserts are ideal for many applications, but they are not always the best fit for every workflow or environment.
Depending on how your equipment is used, cleaned, transported, or updated over time, other interior systems may provide better organization, flexibility, or long-term usability.
Not sure which is right?
We’ll recommend the best option based on your use case.
Stop Equipment Damage Before It Happens
Tell us about your equipment. We’ll design a solution that protects it, organizes it, and works in your real-world conditions.
custom foam faqs
How do I know which foam is right?
We evaluate your equipment, environment, and usage to recommend the best material—no trial and error.
What’s better: foam or thermoformed trays?
Foam protects against impact. Trays improve organization. Many projects benefit from both.
Can I customize branding?
Yes, logos, colors, and labeling are built directly into the insert.
How long will the foam last?
Engineered foam lasts significantly longer than DIY or cubed foam, especially in high-use environments.
What’s the typical turnaround time?
Varies by project complexity, but most custom solutions are completed in 1–3 weeks, including design, prototyping, and production, all handled in-house.
Can you make foam inserts for Pelican cases?
Yes. CH Ellis is an authorized Pelican distributor and manufactures custom foam inserts for Pelican cases and most other major hard case brands. We can also retain existing ones.