What a foam insert is and why you need one
A foam insert is a piece of foamed polyethylene with cavities cut to fit your items exactly. It does three things: keeps the contents still, absorbs impact if the case is dropped, and shows in a second whether anything is missing. A firearm does not knock against the case walls, tools do not get lost in the drawer, and a gift set reaches the customer the way you packed it.
We have been making foam inserts in Dnipro, Ukraine, since 2017 — more than 10,000 so far. We started with inserts for our own cases and safes; today we cut for shooters and military units, service shops and manufacturers, brands and equipment makers, from one piece to runs of thousands.
Applications
- Gun case foam — pistols, rifles and shotguns in a case; barrel rests and pistol holders for safes.
- Tool drawer foam — tool cart and cabinet drawers, power tool cases, shadow boards for 5S.
- Drone case foam — DJI, Autel, FPV, Starlink; production runs for units and UAV makers.
- Case foam — Pelican, Nanuk, MAX and any case by its inside dimensions.
- Box inserts — gift sets, cosmetics, electronics; no die, from 1 piece.
- Equipment and instruments — anything that has to be shipped and stored without damage.
Don’t see your item? Send a photo and we will work it out.
How we work
- You send top-down photos of the items with a ruler in the frame, the inside dimensions of the case or box, and the quantity. Or DXF/STEP files, or the item itself for measuring or 3D scanning. Or a layout from the online constructor.
- We quote prices for several materials, with lead times.
- We agree on the layout drawing and, for production runs, a test sample. Changes are made before cutting.
- We produce: contract, prepayment, CNC cutting, packing, dispatch.
Details: How to order.
How we cut and why it matters
We use a CNC table with an oscillating knife. The blade vibrates at high frequency and goes through foam up to 50 mm thick in a single pass: a clean edge without the dust or melted edges a laser leaves, and without the ragged edge of hand cutting. Tolerance from 0.5 mm on flat material; on thick or warped sheets up to 2 mm, typically 0.5–1 mm. Either way, the cavity holds the item rather than sitting somewhere near it.
There is no die, so one piece is priced as one piece and the first batch does not pay for tooling. Complex contours, stepped cavities and multi-layer inserts are possible.
Materials
| Material | Thickness | Use |
|---|---|---|
| Cross-linked PE foam (Hungary) | 5–50 mm | Cases, firearms, optics, drones — even texture, clean look |
| Cross-linked PE foam (Ukraine) | 5–50 mm | Tools, safes, production and transport inserts |
| PE + EVA | 20–50 mm | Premium cases, displays — EVA surface at close to PE price |
| Non-cross-linked PE foam | 10–40 mm | Boxes, transport packaging, test runs — the lowest cost |
Colours: black, grey, white. Two-colour inserts are made by combining layers. See Materials.
Who we work for
- Private customers — one case for a firearm, drone or tool set.
- Businesses — product packaging, gift set inserts, test runs from 1 piece.
- Service shops and manufacturers — tool organisation, parts trays between operations.
- Case and safe makers — production sets for your models.
- Defence sector — packaging for UAVs, radios, optics and spare parts. Defence packaging foam →
What to send for a quote
- Top-down photos of the items on a flat surface, with a ruler or tape measure
- Inside dimensions of the case, box or drawer (length × width × depth) or its model
- Quantity and required date
- DXF / STEP / PDF files, if you have them
We take it from there.
