Custom Foam Inserts

A reliable source for Custom Carrying Case information and leading Custom Carrying Case Companies & Manufacturers.

To best protect a delicate or intricately designed product, we recommend custom foam inserts over stock foam inserts. This is because they can so easily and so thoroughly be manufactured to fit your product. Read More…

Custom Foam Inserts Foam inserts are inserts made from materials like polyurethane, polyester and polyethylene. Their main objective is to provide a cushion to products in transition, such as cameras, laptops, knives, telescopes and virtually anything else that needs to be held when not in use. It is quite common to find foam inserts inside both carrying cases and shipped boxes. They range from light duty to heavy duty. Examples of carrying cases designed with foam inserts include: tool cases, instrument cases, shipping cases, medical instrument cases, presentation cases and tradeshow cases.

Leading Manufacturers

Uxbridge, MA  |  888-883-0107

New World Case provides multiple styles of carrying cases from respected case manufacturers like Platt, Hardigg, Pelican, Orbus, Nanuk, Smartpak, Ultraform, Nanuk, Zarges & Jelco. Our cases are made with durable metal and plastic exteriors so you can transport and ship with ease. When looking for quality carrying case manufacturers at affordable prices, look no further than New World Case.

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New World Case, Inc. $$$

Clinton, IA  |  563-242-1801

Custom-Pak produces over 10 million carrying cases per year, offering the best value combined with a huge selection of options for carrying cases, consumer product packaging & stock cases. Design team provides the perfect fit for all your important & sensitive items, meeting requirements such as flame retardance, electro-static dissipation, FDA medical or food approvals.

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Custom-Pak, Inc. $$$

Santa Maria, CA  |  805-928-8840

One of the top carrying case suppliers, Princeton Case West provides quality carrying cases, custom cases, shipping cases, plastic cases, aluminum cases, tool cases, computer cases, instrument cases, transit cases and ATA cases. Princeton Case West offers custom foam inserts for varying applications. From design to delivery, Princeton Case West offers the complete package at affordable pricing.

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Princeton Case West $$$

West Chester, PA  |  610-436-4750

Amongst carrying case companies, Packateers, Inc. is known as tough competition due to quality-constructed carrying cases and affordable prices. Providing a wide range of carrying case products including custom carrying cases, hard cases and soft cases, Packateers is one of the most resourceful carrying case manufacturers. Packateers carrying cases offer dependability, adaptability and durability.

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Packateers, Inc. $$$

Chicago, IL  |  773-585-1164

Our cases come in various configurations such as soft sewn cases, hard cases, model cases, exhibit cases, and more. We are experts in contract sewing and there is no project too complex for our experts. With manufacturing experience dating back to 1994 we are confident we can provide you with a top of the line custom carrying case.

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Custom Case Company, Inc. $$$

Floyds Knobs, IN  |  812-406-0321

We have nearly 30 years of experience designing and manufacturing carrying cases for fortune 100 companies such as Microsoft and Intel, while also helping countless startups launch new and innovative products as they grow their business. Our stringent quality control, domestic customer service and design team, and hassle-free logistics have made us an industry leader in custom case solutions. Contact us today and we’ll show you why our customer retention rate is the highest in the business.

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Tetrafab $$$
placeholder image New World Case, Inc. Custom-Pak, Inc. Princeton Case West Packateers, Inc. Custom Case Company, Inc. Tetrafab

First, custom foam inserts can be made using a great many processes. These include CAD routing, hand prototyping, steel rule die cutting, convoluting and waterjet cutting. All of these processes allow for custom foam inserts with precise dimensions. For extra deep cuts and exceptionally large products, manufacturers can make wire cut foam inserts. They can make them as thick as 50 inches or more.

In addition, manufacturers can design them with special properties, like anti-staticity, or special additions, like an adhesive backing. Foam properties like polyethylene can range in appearance from nearly transparent to opaque. Because of this, and because they accept modifications, custom foam inserts can also be infused with a wide variety of colors.

Custom Foam Inserts Custom Foam Inserts - New World Case, Inc.

Custom foam inserts provide products on the shelf, products in transit and regularly stored products with the best possible shock absorption rate, the ideal density and the longest service life. Manufacturers can make them durable and safe enough even to cushion potentially dangerous items like rifles, firearms, hand grenades, bows and crossbows. They can also fabricate them with special shapes, like those that hug the curves of stethoscopes or pressure gauges. This diversity makes custom foam inserts ideal for use in many industries, including military and defense, music, art supply, medicine, electronics, biotech, sports, retail and trade, engineering and IT.

In contrast to all of this, stock foam inserts are often ill-fitting and not made with the right material for the products they are meant to house. This leads to them wearing out relatively quickly. It also opens up products to the possibilities of dislodgement and/or damage. Neither are stock foam inserts attractively colored. With them, you get what you get. This is why, if you want the best protection and the best look, you will seek out custom foam inserts.

To begin work on your custom foam insert, we recommend that you connect with a reputable custom foam insert manufacturer and then do one of three things: 1) send in a drawing, 2) construct and send in CAD layout or 3) send in the part you need protected and let the manufacturer design the insert for you. Find the right manufacturer for you by checking out the list of top quality companies that we have listed below. Good luck!

Custom Foam Insert Informational Video