Custom Foam Inserts for Cases (Foam Cushioning Guide)
Custom foam inserts are the most effective solution for protecting sensitive equipment during transport and storage. At Cases2Go, we specialize in engineered foam cushioning systems designed to absorb shock, reduce vibration, and securely integrate your equipment within transit and custom shipping cases.
From military and medical equipment to electronics and AV systems, our custom foam packaging solutions are tailored to meet the demands of real-world environments. Whether you need a single prototype or large-scale production, our in-house engineering and fabrication team delivers precision-designed foam interiors built for performance.
Our cases are configured to meet an endless set of specialty requirements with engineered foam inserts and custom case interiors to fully integrate and protect your equipment.
The very heart of our operation can be found in our state of the art production facility. Our customers have come to rely on us not only for our sensible and innovative foam solutions, but also our focused response to their urgent and often changing needs. Whether you require a single prototype or thousands of units – our packaging sales specialists work in tandem with design engineers and highly-skilled packaging and manufacturing specialists to produce a design that is right for your application.
Looking for a complete solution? Our foam inserts are designed to integrate seamlessly with
transit cases,
rackmount cases, and
turn-key integration solutions for transporting sensitive equipment, creating fully engineered equipment protection systems.
Why Custom Foam Cushioning is Critical for Equipment Protection
During transit, equipment is exposed to shock, vibration, and environmental stress. A properly engineered foam cushioning system absorbs impact forces and prevents movement inside the case, reducing the risk of damage.
Custom foam inserts are designed based on your equipment’s size, weight, fragility, and transport conditions. This ensures maximum protection and long-term durability.
Types of Foam Used in Custom Case Inserts
Foam selections include a large inventory of closed cell, Polyethylene and open cell Polyurethane foams with density ranges to support light to heavy products. With a wide range of foams available our designers are able to offer our customers a complete package solution which not only protects but looks appealing. Choosing the proper foam material for your requirements
Polyethylene Foam (PE)
(Also referred to as “PE”) Polyethylene foam is a firm, denser, closed-cell foam, best for general use and heavier equipment. Polyethylene foam inserts for cases are often used for packaging applications due to its excellent vibration dampening and insulation properties.
Crosslinked Polyethylene Foam
Is highly dense closed cell foam characterized by its compact feel and resistance to water. It has many of the same properties as polyethylene foam but also has the ability to protect class “A” surfaces and is consequently used extensively in the packaging of medical products and equipment.
Polyurethane Foam (PU)
(Also referred to as “PU”) Polyurethane foam is a softer, open-cell foam, best for sensitive equipment that is lighter in weight with a high fragility and lower drop height maximums. It is available in two primary types, polyether and polyester, in a range of densities.
Anti-Static Foam
Available in both Polyurethane and Polyethylene versions. These specials foams inhibit the buildup of static electricity and help dissipate static charge, primarily used for the protection and packaging of sensitive electronic components and products. This offers a lower range of electrical resistance than static dissipative and conductive foams.
Conductive Foam
A grade of foam that offers the highest level of electrical resistance, and provides excellent EMI shielding. Conductive refers to the material's ability to drain away charges instantly.
Static Dissipative Foam
A grade of foam in the middle range of electrical resistance, which is greater than anti-static and lower than conductive.
Poly-Styrene Foam
Commonly known as Styrofoam. Is an ultra-dense foam, which can be molded to customer specifications.
MIL-SPEC Foam Packaging Standards
Cases2Go supports military and government packaging requirements with foam materials that meet MIL-SPEC standards, including:
PPP-C-1752 Type I, Class 2, Color Gray, Density 2pcf (normal) or 4pcf (high density)
MIL-P-26514 Type I, Class 2, Color Gray, Density 2pcf (normal) or 4pcf (high density)
These specifications ensure performance in demanding environments where durability, shock resistance, and reliability are critical. Please contact our sales specialists with your MILSPEC requirements.
Types of Foam Cushioning Systems
Cases2Go specializes in providing solutions for the most complicated case and foam cushioning challenges.
Foam Filled
The case is filled with separate layers of any one type of the above foams.
Foam Lined
The case is lined with a layer of any one type of the above foams. (Commonly 1" or 2".)
Diced Foam Filled
The case is filled with separate diced foam layers, usually polyurethane foam which individual blocks of foam can be removed (pinch and tear) to create desired cavities.
Custom Cushion Systems and Custom Foam Inserts
Based on the equipment specifications provided, our sales specialists and designers will create a custom foam insert specifically for your items using any one or a combination of the above foams. Our precision fabrication capabilities enable us to provide unparalleled accuracy and quality for custom designed case interiors.
Additional Custom Foam Cushioning Options
Straps (Woven or Velcro)
Commonly used to secure items in a lid cushion. Woven straps can also be used in conjunction with a lift out tray to provide easier access to compartments below.
Lift-Out Trays
Maximize available depth, compartments and configuration options.
Hard Partitions
Spreads equipment load; protects and supports compartments.
Frequently Asked Questions About Foam Inserts
What is the best foam for protecting equipment?
Polyethylene foam is best for heavier equipment, while polyurethane foam is ideal for lighter, more fragile items.
Are custom foam inserts better than pick-and-pluck foam?
Yes, custom foam inserts provide a precise fit and superior protection compared to generic pick-and-pluck foam.
Can foam inserts be designed for specific equipment?
Yes, Cases2Go specializes in designing foam inserts tailored to exact equipment dimensions and requirements.
Ready to get started?
Design a Custom Foam Insert for Your Equipment
Every piece of equipment is different, which is why Cases2Go offers fully customized foam engineering solutions. From concept to production, our team works with you to design a solution that protects, organizes, and enhances your equipment transport system.