How to use pick ‘n’ pluck cubed foam inserts

Whilst GWP Protective focus on creating custom engineered foams that are precisely tailored to specific items, for one-offs and very low volumes pre scored or “cubed” foam inserts are a much more cost-effective option.

Commonly supplied in Peli™ & Storm case™ options (where the cubed foam is called PICK N PLUCK™ foam), this type of foam insert is easy to modify yourself to create approximate recesses to the shape of the items you are looking to safely store / transport.

As with engineered Plastazote®, this type of foam can be used to enhance the protection of items stored within the case by adding an enhanced level of cushioning against impact. They can also be used for keeping multiple items organised within a single case.

The foam inserts are manufactured in such a way that the end user of the case can tailor the foam to practically any item, creating a truly bespoke protective case system at considerably lower cost than fully engineered solutions.

This guide will show you how to use pre-scored foam inserts and therefore get the most out of your protective equipment case.

Before going through the step by step process for creating your perfect cubed or PICK N PLUCK™ foam insert, it is important to first explain what this type of foam is.

Usually, when you purchase a case with the option of cubed foam, you will receive at least 2 pieces of material (although it is often more for the larger cases).

The bottom or base layer will be a heavier, denser foam that is used to provide cushioning at the bottom the case. This does not need modifying and should be used as supplied.

The upper layers will comprise of what is known as the cubed foam. This foam is “pre-cut” into 1-centimetre cubes, which are still partially joined together.

What this means is that these smaller sections of foam can be removed neatly and easily, allowing for detailed profiles to be created. It also ensures as well as different shapes, different depths can be created in the pre-scored foam insert.

Excellent results can be achieved if a little time and patience is used with the resulting protection offered by the case being very effective. The below guide provides a step by step “how to” guide on getting the best results from your “diced” foam inserts.

Please continue reading to find out how to use this type of foam inserts.

Please see below for a successful, 6 step process to creating your tailored cubed foam inserts.

Remember to take your time and avoid distractions to get the best results.

The first stage is to mark out the shape(s) you wish to remove from the foam.

Lay out the items on the foam to work out the best configuration/orientation within the cases (this is particularly important when working with multiple items).

As a rough guide, for light weight items leave a minimum separation of 1/2″ (1.5cm), especially delicate light weight items (e.g. cameras, laptops) the suggested separation is 1″ to 1-1/2″ (2.5cm to 4cm), and for heavier items (with a weight of approximately 10 to 20 lbs.) leave 1-1/2″ to 2″ (4cm to 5cm) of separation.

One other thing to bear in mind is that, for maximum protection, it is also best to keep equipment inside the pre-cut grid area.

Once you have decided on your preferred layout, it is wise to mark the boundaries of the areas to be removed. Cocktail sticks, toothpicks or pins/needles all work well for the purpose of this.

With the various objects in place, insert the position markers around the object.

When the object you are marking out is halfway between one row of the pre-cut section sections, always choose to go in one row towards the object. This will ensure a much more snug fit and offer greater protection of the items being transported.

Remember to always err on the side of caution. If the space is too small, it is always possible to remove more foam at a later point (as it is obviously a bit harder, although still possible, to put it back in).

While it is not necessarily required, many people find it can be helpful to “pre-cut” the foam before plucking / removing it.

Although it is quite easy and straight forward to remove the pre-scored foam without doing this, the rows of foam cubes are stuck together quite well and pre-cutting the profiles can eliminate the risk of removing additional sections of foam accidentally.

Always remember to take your time and, if you are careful, you can skip this step if you feel confident enough.

With the layout and areas of foam to remove identified, it is now time to start removing the required sections.

To pluck out the foam, simply place your fingers into the gap between the rows you have marked off and with a steady, consistent action begin pushing down and pulling towards you. You should find that the foam begins to separate before breaking off.

It is a good idea to try and remove large sections of foam at a time, as opposed to the individual cubes.

This will provide 2 benefits, firstly saving you time, but will also give you large blocks of foam that you can use elsewhere if required.

It may be possible that you can use some or all of the “excess” foam to improve the fit by re-adding it, as it can be stuck back in with a suitable glue or spray adhesive.