Custom Foam Inserts

custom foam inserts from Wilson Case

Custom Foam Inserts

Wilson Case Waterjet Inserts

Waterjet, CNC Router &
CNC Knife Cutter

custom foam inserts from Wilson Case

Custom Foam Inserts
for Waterproof Cases

Wilson Case has the expertise to cut foam inserts for cases that can meet exact requirements for any application, any quantity, any size, and any container, whether you need inserts for your custom Wilson Case solution or as part of your product packaging. We have the expertise, experience, and technology to satisfy your most challenging foam component, packaging, and product requirements. We are proud to serve the U.S. government/military and commercial industries including medicine, aerospace, automotive, packaging, computers, and numerous other markets.

When Wilson Case is called upon to manufacture a custom shipping case for a unique item, we design the whole thing for maximum protection inside and out. The inside part of the equation is where our custom-cut foam case inserts come in. Whether you need high-quality interior cushioning for Wilson Case products, another case you already own, or as part of your product packaging, we can deliver custom case inserts of any size, for any requirement, at a competitive price and with excellent lead time.

We use the highest-quality foam material in all of the custom foam inserts we make for shipping cases, and we offer a variety of foam options, including ester, etha, anti-stat, crosslink, PSA, and flame-retardant foam. Our engineers use solid modeling technology and CNC tools to design each foam insert for a precise case fit and ultimate security. Our main production facility has water jet cutting, CNC router cutting, and knife foam cutting capabilities to ensure that we can sculpt and contour any shape with edges as smooth and fine as possible.

We offer custom-cut foam shipping case inserts for both one-off orders and large production runs. Our flexible scheduling and full-service teams enable us to meet nearly any lead time—that’s just one of many things that separates us from our competitors. Whatever your shipping needs are, Wilson Case promises to protect your cargo and make you look good.

Computer Controlled Routing (CNC)

Computer-controlled routing (CNC) is a design process that uses computer-guided drill and router bits for cutting and shaping many materials. Utilizing CNC routing gives us the ability to manage your project’s production start to finish, from initial design to a prototype to the finished product. In addition to foam, we can work with substrates like plastics and aluminum to customize precision parts in small quantities without typical tooling expenses. CNC routing is very useful when fabricating custom foam inserts for protective cases and other specialty packaging applications because the routing heads can easily fabricate multiple cavity depths.

Water Jet Cutting

Our water jet cutting technology is capable of slicing into any type of open-cell and closed-cell foam using a jet stream of water, forced through a tiny nozzle at a high pressure of 60,000 PSI, to perform precision cutting and leave smooth, extremely accurate edges. Our water jet services are available to any customer for any application. It’s an environmentally friendly solution for nearly every cutting need, and it’s less expensive than laser die cutting.


Custom Foam Insert Gallery

Take a look at some of the custom foam inserts we’ve designed for shipping cases of all shapes and sizes.

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Custom-Cut Foam Inserts for Your Industry

We have extensive experience with designing custom shipping cases and foam inserts to meet the unique shipping challenges of various industries, including the following.

Aerospace Foam Case Inserts

We can design foam inserts to protect everything from drones to space suits to large aircraft parts.

Athletic Foam Case Inserts

Transport your essential athletic trainer or sports equipment with our custom foam inserts made to your specifications.

Automotive Foam Case Inserts

Protect your expensive and intricate auto parts in transit with custom-cut foam inserts.

Computer Foam Case Inserts

Whether you’re shipping a whole PC or a collection of small microchips, our custom foam shipping case inserts will keep your items snugly in place without raising the temperature inside the case.

Medical Foam Case Inserts

Ship medical devices and supplies safely with custom foam insert solutions.

Military Foam Case Inserts

We have a long history of working with the U.S. government to create custom-cut foam inserts for military supplies and equipment.

Packaging Foam Case Inserts

Manufacturers can use our custom case inserts as part of the packaging for their goods.

Robotics Foam Case Inserts

Robot manufacturers can use our custom case inserts as part of the packaging for their goods, for transporting machinery or for transporting demonstrational products.

Custom Foam Case Insert Quote Request

Enter your contact information below to receive a quote for a custom foam case insert. Please include a description of what you need your foam insert to accomplish, and if possible, the dimensions and/or an image of the item you plan to ship. We’ll respond with your custom quote shortly.


If you have questions about our custom-cut foam inserts or you aren’t sure how to best describe your needs, contact Wilson Case. We’ll help determine the best option for your business.