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 case inserts.
The Process
1. Choose A Custom Foam Insert
Pick ‘n pluck foam is by far the easiest and most often used method to produce pockets in personal equipment cases. Most Pelican, Pelican Storm and SKB injection molded cases come with pick and pluck (or cubed foam). These pre-scored pluck foam pieces come in different layer thicknesses. Depending on the size of the case there may be anywhere from one to six or seven foam layers in a case. There is typically one solid piece on the bottom of these cases which should never be cut through. Some of these cases will come with soft layered foam inside instead of pluck foam, so check the description for each case model.
2. Determine the best layout for your equipment.
Determine the best layout for you equipment. Depending on the fragility of the individual pieces try and leave a minimum of 1” between each piece. For the more fragile pieces 1 ½” -2” is advisable. For cables and other non-sensitive equipment an accessory compartment will save interior space.
3. Trace around each piece using a light coloured marker such as a Sharpie or equivalent
Again, remember to leave an appropriate amount of foam between each piece. Place the more fragile pieces away from the sides of the case if possible. Cables and cords can go nearest the inside walls.
Toothpicks or any such tool may be used. Each piece will probably require different depths, so be careful to only pluck out to the desired depth. You can place the plucked out pieces back under the equipment to adjust for the desired height.
