Custom Cut Foam Inserts for Any Brand Case
Tell us your case make and model and what goes inside. We CNC-cut a solid foam insert with an exact pocket for every item – for Pelican, Apache, Nanuk, SKB, Milwaukee PACKOUT, tool chests and just about any hard case.
- Cut in-house in Pomona, CA
- Any case brand or size
How custom foam cutting works
No templates to print and no knife work. You send the details, we program the cut, and you get a custom case foam insert that drops straight in.
Tell us the case
Send the brand and model number (for example Pelican 1510 or Apache 4800). No model number? Send the interior length, width and depth.
List your gear
Tell us what goes in – a photo of the items laid out, plus sizes for anything critical, lets us plan pockets, finger pulls and spacing.
Approve the layout and price
Build it yourself in the online foam designer and the price updates as you go, or send your gear list and we reply with a layout and price. Nothing is cut until you approve it.
We CNC-cut and ship
Your insert is routed on our CNC machine in Pomona, CA from closed-cell cross-linked foam and shipped to your door.
Precision CNC foam cutting, not pick and pluck
Pick and pluck foam leaves ragged cubes and gaps that let gear shift. CNC foam cutting routes each pocket to the shape of the item, with clean vertical walls and a flat floor, so everything sits tight and stays put in transit.
- Exact-shape pockets for each tool, lens, firearm, meter or accessory
- Finger pulls where you need to lift items out
- Multi-layer builds for deep cases – a cut layer on top of solid base layers
- Closed-cell cross-linked foam that resists moisture, dust and compression
- Repeatable – order the same custom foam insert again for every case in your fleet
Custom foam for any brand case
We cut to your case’s interior, so the brand does not matter. These are the cases we are asked about most:
Pelican case custom foam
Custom Pelican foam for the 1120, 1150, 1200, 1400, 1450, 1500, 1510, 1520, 1550, 1600, 1610, 1650, 1700, 1750 and Pelican Vault V700/V770/V800. Prefer reconfigurable foam? See our Pelican case foam inserts.
Apache case custom foam
Custom foam inserts for Harbor Freight Apache 2800, 3800, 4800, 5800 and 9800 cases – or shop ready-to-fit Apache case foam.
Milwaukee PACKOUT
Custom-cut layouts for PACKOUT tool boxes, drawers and organizers. Pre-cut and uncut PACKOUT foam inserts are also in stock, and the 48-22-8450 tool case gets a replacement insert cut to its interior.
Nanuk, SKB, Plano & Seahorse
Send the model number and we will cut a replacement insert to match the interior of your Nanuk, SKB, Plano, Seahorse, Condition 1 or other waterproof hard case. See Plano replacement foam and SKB & Nanuk case foam.
Tool chests & drawers
Shadow foam for toolbox drawers from any maker – give us the drawer’s inside dimensions and the tools. More in tool box foam inserts.
Gun & rifle cases
Custom gun case foam for pistol cases, long rifle cases and range bags with pockets for optics, magazines and accessories. See also pre-cut gun case foam.
Custom shadow foam for tools
Shadow foam gives every tool its own outlined pocket, so a missing wrench is obvious the second you open the drawer. It is the fastest way to run a clean shop, a 5S/lean work cell, a flight line or a service truck where tool control matters.
Send us the drawer or case size and a photo of the tools laid out. Ask about contrasting colour layers when you send your tool list.
What we cut custom foam inserts for
Firearms & optics
Pistols, rifles, scopes, red dots, suppressors and magazines held without movement.
Cameras & drones
Bodies, lenses, gimbals, drones, controllers and batteries in one organised layout.
Tools & equipment
Power tools, hand tools, torque wrenches, bits and sockets for service kits and job boxes.
Test & measurement
Meters, gauges, calipers, probes and sensors shipped and stored safely.
Medical & lab
Instruments and devices kept in a fixed, checkable layout.
Audio, AV & collectibles
Microphones, interfaces, graded cards, watches and display pieces.
How to measure your case for custom foam
If you know the brand and model, that is usually all we need. For any other case:
- Remove the old foam and measure the interior length and width at the bottom of the base, wall to wall.
- Measure the depth of the base and the lid separately.
- Round to the nearest 1/8" and note any hinges, ribs or rounded corners.
- Lay your gear on a sheet of paper and take a straight-down photo to send with your request.
Step-by-step: how to measure a hard case for replacement foam.
Custom cut foam vs pick and pluck vs reconfigurable foam
| Custom CNC-cut foam | Pick and pluck foam | RAGAR reconfigurable foam | |
|---|---|---|---|
| Fit | Exact pocket for each item | Blocky, depends on your plucking | Blocks re-arranged around the item |
| Best for | A fixed kit that never changes | A one-off, low-cost layout | Gear that changes often |
| Change the layout later | Order a new cut | No – plucked cubes are gone | Yes, as often as you like |
| Shop | – | Replacement foam | Custom foam inserts |
Not sure which one you need? Read pick and pluck foam vs reconfigurable foam, or check the case foam size chart.
Popular custom foam inserts
- Apache 4800 custom foam insert17-7/8" x 12-7/8" interior
- Apache 3800 custom foam insert14-7/8" x 10-5/8" interior
- Pelican Vault V800 custom foamDouble rifle case
- Pelican Vault V770 custom foamSingle rifle case
- Pelican 1450 trading card foamGraded slab storage
- DeWalt ToughSystem 2.0 foamTool boxes & shallow tray
- Plano replacement foamGun & hard cases
- SKB & Nanuk case foamReplacement inserts
- Custom foam packaging insertsFor businesses
- Shadow foam for toolsGuide
- How to cut foam for a Pelican caseGuide
Custom foam cutting FAQ
How much do custom foam inserts cost?
The online foam designer shows the price live as you build; a gear list gets a layout and price by email. Price depends on the foam area, the number of foam layers and how many pockets the layout needs. Send your case and gear details and we will reply with a price before anything is cut.
Can you cut custom foam for a case you do not sell?
Yes. That is what this service is for – we cut to the interior of your case, whether it is a Pelican, Apache, Nanuk, SKB, Plano, Seahorse, Milwaukee PACKOUT, a tool chest drawer or an unbranded case.
Do I need to send you my case or my gear?
No. For most cases the brand and model number is enough. For other cases, send the interior measurements and a straight-down photo of your gear laid out, plus sizes for anything that must fit tightly.
What foam do you use?
We cut closed-cell cross-linked polyethylene (XLPE) foam. It is firm, resists moisture and does not crumble like the open-cell foam found in many pick and pluck inserts.
How do I cut foam for a Pelican case myself?
You can trace your gear onto the foam and cut with a long sharp blade or hot knife, keeping the blade vertical and cutting in shallow passes. It is slow and hard to get clean walls, which is why many owners choose CNC foam cutting instead. For a do-it-yourself layout without cutting, try our reconfigurable foam inserts.
Can you cut custom gun case foam?
Yes. We cut custom gun case foam for pistols, rifles, shotguns, optics and magazines – tell us the exact firearm models and accessories, or place them from the gear library in the online designer.
Can I order the same insert for several cases?
Yes. Once your layout is set up we can cut matching inserts for a whole fleet of cases – mention the quantity in your request.
Need foam that fits now?
Design a CNC-cut insert online in minutes, or shop RAGAR reconfigurable and pre-cut foam. Everything ships from Pomona, CA.
Pelican, Apache, Nanuk, SKB, Plano, Seahorse, Condition 1 and Milwaukee PACKOUT are trademarks of their respective owners. RAGAR is not affiliated with or endorsed by these brands; model names are used only to describe compatibility.