Custom Pelican Case Foam: 78 Models, Exact Sizes

Why a Pelican case needs a proper insert

Pelican is the benchmark hard case, but the standard pick-and-pluck foam is a compromise: cavities come out stepped, cubes tear off and mistakes cannot be undone. A cut insert follows the outline of every item, lasts for years and looks like part of the case.

We took the dimensions of 78 Pelican models — Protector, Air, Storm and Micro — from the manufacturer’s 3D models (STEP): wall draft, corner radii, wheel wells, ribs and lid bosses. So we cut the insert without test fitting — the model name and photos of your items are enough.

Supported models

Protector, HardBack: 1080, 1095, 1120, 1150, 1170, 1200, 1300, 1400, 1430, 1440, 1450, 1460, 1470, 1490, 1495, 1500, 1510, 1520, 1550, 1560, 1600, 1610, 1620, 1630, 1640, 1650, 1660, 1670, 1690, 1700, 1720, 1730, 1740, 1750, 1770, 1780. Air: 1485, 1506, 1507, 1525, 1535, 1555, 1556, 1557, 1595, 1605, 1606, 1607, 1615, 1637, 1745, 1755. Storm: iM2050, iM2075, iM2100, iM2200, iM2275, iM2300, iM2306, iM2400, iM2450, iM2500, iM2600, iM2620, iM2700, iM2720, iM2750, iM2875, iM2950, iM2975, iM3075, iM3100, iM3200, iM3220, iM3300. Micro: M40, M50, M60.

Not on the list? Send the model name or inside dimensions and we add it to the library.

What goes in

Photo and video gear, optics, firearms, drones, instruments, medical equipment, presentation kits. Dedicated layouts: firearms, drones, equipment.

How we make it

Case model — from the library. We only check whether the factory base and lid foam stay.
Item outlines — a top-down photo with a ruler, or from the library by model. Clearance 1–2 mm.
Layout — cavities in one or two tiers, finger cut-outs. You get a layout to approve.
Cutting — CNC oscillating knife, PE/EVA foam up to 50 mm, tolerance from 0.5 mm. The insert fits the case snugly without fixings.

Custom Pelican foam inserts start at UAH 499; the exact price follows your sketch.

Materials

Task	Material	Thickness
Protector, deep	Cross-linked PE (Hungary) or PE+EVA	50 mm cavities, 2 tiers if needed
Air, shallow	Cross-linked PE	30–40 mm cavities + 10 mm base
Working kit	Cross-linked PE (Ukraine)	40–50 mm

Colours: black, grey, white. See Materials.

What to send

Pelican model
Top-down photos of the items with a ruler, or a list of models
Quantity

Or make the layout in the online constructor — Pelican cases are in the case list.

Frequently asked questions

Can it replace the pick-and-pluck foam that came with the case?

Yes — this is the most common request. Pick-and-pluck cubes give stepped cavities and tear off; we cut a solid insert to fit your items exactly, to the size of the factory insert. The factory base and lid layers can stay.

How do I send the sizes of my items?

A top-down photo on a sheet with a ruler, or a list of models (cameras, lenses, instruments — many outlines are in our library). Or lay them out yourself in the online constructor, where Pelican cases are in the list.

Pelican Air cases are shallower — which thicknesses?

For Air cases we use 30–40 mm PE foam for the cavities and 10 mm for the base, to keep the depth. For Protector 1600/1650 — 50 mm and two tiers.

How many pieces?

From one. For rental houses, film crews and units — runs with an identical layout.

Do you ship outside Ukraine?

Write to us with the destination — we reply with price and delivery options.

Send a sketch — we reply with prices in several materials

01 · Hand sketch, photo, PDF, DXF or STEP

02 · Prices in 2–3 materials

03 · Drawing and a sample for approval

04 · Contract, production, shipping

Sample in 1–3 working days · from 1 piece · inserts from UAH 499

Custom Pelican case foam inserts