Custom Foam Inserts

Carry Cases Plus is your one-stop shop for custom foam, no matter how you choose to tackle your project! Use the chart below to choose the option that's right for you:
Let us put our decades of foam-fabrication experience to work for you! Whether you opt to use or send us your items so we can create the perfect design for you, your custom foam will be expertly manufactured in our 39,000 sq. ft factory using our state-of-the-art Case Foam fabricating equipment.
Do it yourself Foam Carry Cases Plus Pro Design
Call us at 973-742-8118

Purchase a foam-filled case or case foam. Use a utility knife or Diced/cubed cuts to customize your own foam.

Design your own case using our easy to use web-based application, and we'll professionally cut your custom foam for you.

Send us your items and let our case engineers lay out, design and custom cut the perfect foam insert for you.
Look for the Diced/Cubed option on our case pages, or choose from our separate custom foam options:

Look for the MyCaseBuilder option on our case pages, or visit the MyCaseBuilder site and learn more!
Let us know the details of your Pro-Design project by filling out our contact form and one of our case engineers will contact you.
Your Custom Design projects can look like these!
Choosing the proper foam is essential to the security of the items you store in your case. Use this guide below to help you choose the perfect combination for your needs.

Types of foam

We offer two different types of standard foam: PE (Polyethylene) and Ester (Polyurethane). PE foam is fairly dense, and only slightly pliable. It offers a secure, snug fit. Ester foam is much more spongy and forgiving, exhibiting excellent shock absorption. While we have found that the PE foam is suitable for most designs and recommend it when in doubt, you can use the comparison chart below to help decide which one is right for your design:

PE (Polyethylene) Foam vs. Ester (Polyurethane) Foam
Black PE Foam

  • Dense and long-lasting; easy to cut with a knife.
  • Good for medium to heavy-weight objects that need to be secured in place (example: handgun).
  • Good for objects that can absorb a modest amount of shock without being damaged (example: electric drill).
  • Available in Solid and Anti-Static options.
Charcoal Ester Foam

  • Soft but durable foam.
  • Good for more delicate objects that may break on modest impact (example: crystal stemware).
  • Good for more complex or irregularly-shaped objects (example: digital SLR camera).
  • Available in Solid, Diced/Cubed, Convoluted and Anti-Static options.

Case Foam Options

There are many different ways to configure the foam in your case. Use the information below to help determine which one is right for your needs.

Interior Foam Options

Convoluted / Diced

Solid / Solid

Convoluted / Convoluted
Solid foam pads make up the base foam of your case and come in both PE and Ester. For the bottom, a 1/2" solid base pad is standard to keep items from coming into contact with the case. For smaller cases, another single solid pad fills the remaining space. For larger cases, multiple pads may be used in order to accommodate different sized items with ease.

Solid foam is appropriate as lid foam in situations where case items all sit flush with the surface of the base. It can also be cut with a utility knife to make your own custom cavities.
Convoluted (egg-crate) foam is made from soft but sturdy Polyurethane. It is most used as lid foam because of its ability to gently secure in place any items that may protrude above the surface of the base foam. It can also be used as a base foam for thinner cases, and is good for holding thin objects so no movement occurs during transport.
Create your own insert! Diced/Cubed cases come with a solid base pad on the bottom, and the remainder filled with Polyurethane Foam that's pre-cut into removable cubes. Simply remove the individual cubes necessary to create a custom-sized space in which to fit your items.

Foam Fabrication Methods

To create your case foam just right, we employ different methods of fabrication using our computer-controlled precision cutting machines.

Foam Cutting Methods
Water-Jet Cut
Nothing matches the speed and accuracy of our double-headed Water Jet cutter. This machine cools, compresses and streams a high-powered 0.020" (0.5mm) wide jet of water that cleanly slices even the most durable foams we offer. Every intricacy of your custom foam design will be picked up by the ultra smooth movement of the jet nozzle, resulting in a perfectly replicated custom cut foam insert.
For the most professional look, foam can be custom cut using steel-rule dies and our in-house die-cutting presses. Die-cut foam is precision sized and smoothly shaped so your items will fit perfectly. From the smallest holes to the tightest curves, die-cut foam is the ultimate choice for optimal protection and look. Die-cutting is the usual fabrication method of choice for large-quantity runs and requires a one time tooling charge.
Wire Cut
For extra deep cases and larger-sized custom foam fabrications, there is no substitute for wire cutting. Our advanced computer-controlled abrasive wire cutting machine allows us to accurately cut foam as thick as 50"! For this method, you can supply your own CAD drawings or we can create one for you that suits your needs. All wire-cut foam fabrications require a one time programming charge.
Knife Cut
For creating prototype samples, fabricating small cases and handling production runs under 25 pieces, an exacting knife cut is the way to go. Our computer-controlled knife cutter is capable of serially producing multiple jobs from a single plank of foam.
Carry Cases Plus is a proud partner of! Whether you need one case or hundreds, MyCaseBuilder is the most cost-effective way to ensure that you get the perfect case for your belongings with a precision that Diced/Cubed foam just can't match.

MyCaseBuilder allows you to design your own custom foam with an easy-to-use online application, and have it custom-cut for you using one of the above methods. Look for the MyCaseBuilder logo on this site to get started creating your own custom foam!