While “Pick ‘N Pluck” (pre-scored open-cell foam) is convenient for a quick fix, it lacks structural longevity. Over time, the small cubes tear and “crumb,” leading to gear shifting and dust accumulation. Custom CNC-cut foam provides a solid, single-piece architecture that holds its shape for years, offering a precise “millimeter-perfect” fit that eliminates movement during high-impact transport.

For heavy industrial tools or telephoto lenses, Cross-Linked Polyethylene (XLPE) with a density of 2.0 lb/ft³ to 4.0 lb/ft³ is ideal. This high-density closed-cell foam prevents “bottoming out” where the weight of the item crushes the foam during a drop, causing it to hit the hard plastic shell of the Pelican case.

No. At Foamkart, our custom inserts are designed with a “pressure-relief perimeter.” We ensure the foam is cut precisely to the interior walls without overflowing or bunching near the rim. This allows the Pelican lid to close fully, engaging the O-ring seal and maintaining the case’s IP67/IP68 waterproof and dustproof ratings.

Yes. Unlike many retailers who only stock foam for current models like the Pelican Air or Protector series, Foamkart can manufacture inserts for legacy cases (e.g., older 1500 or 1600 series). As long as you provide the interior dimensions, we can CNC-route a perfect fit for any vintage or rare hard case.

The G-Factor refers to the maximum acceleration a piece of equipment can withstand before breaking. When designing custom Pelican inserts, we calculate the foam’s static loading. By matching the foam’s firmness to your equipment’s G-Factor, we ensure that the foam absorbs the shock of a 3-foot or 6-foot drop so your gear experiences a “soft landing” internally.

Yes. We offer foams that meet various MIL-SPEC (Military Specifications) for density, flammability, and chemical resistance. Our XLPE (Cross-Linked Polyethylene) is frequently used in defense and aerospace applications because it does not rot, is resistant to fuels/oils, and performs consistently in extreme temperatures from -70°C to 90°C.

The Pelican Air series is designed to be lightweight, which often results in more internal vibration during transit. Custom foam eliminates “rattle damage” by providing conforming support. Instead of the gear vibrating against loose foam, every contour is gripped by the foam, which dampens high-frequency vibrations that could otherwise loosen screws or calibrate optics in transit.

Absolutely. Many pros use a custom foam base for their heavy gear and a Pelican Lid Organizer for cables and smaller accessories. When ordering, simply let us know you have a lid organizer installed, and we will adjust the depth of the base foam to ensure the case closes securely without over-compressing your equipment.

Standard cheap foams can release volatile organic compounds (VOCs) that create a foggy film on lenses and sensors. Foamkart uses low-VOC, chemically inert XLPE and EVA foams. These materials are specifically chosen for high-end electronics and optics because they do not “off-gas,” keeping your camera sensors and screens crystal clear.

To ensure a perfect fit, measure the Interior Length, Width, and Depth at the narrowest points (usually the bottom). It is also important to note the corner radii and any wheel-well or handle protrusions. If you provide the Pelican model number (e.g., Pelican 1510), we likely already have the exact CAD templates in our database.

Yes. For deep cases, we recommend layered foam “cassettes.” We can create stackable foam trays with integrated handles. This allows you to store a drone or large camera body on the bottom layer and a tray of batteries and controllers on the top, effectively doubling your organized storage space.

Yes. Because our XLPE and EVA foams are closed-cell, they are non-porous. You can safely clean your foam inserts with 70% Isopropyl Alcohol, bleach wipes, or standard soapy water. The foam will not absorb the liquid, making it ideal for medical, laboratory, or field use where sterilization is required.