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GWP Packaging

Corrugated cardboard packaging expertise and innovation

GWP Protective

Widest range of protective cases with custom foam in the UK


UK leading independent Correx® packaging manufacturer

GWP Conductive

Providing cutting edge ESD safe packaging for 30+ years

GWP Coatings

Supplying sheet plants with coated corrugated material

Reduce packaging costs

A range of strategies and ideas to reduce your ongoing packaging costs

Protective packaging

Protection for your products and equipment to prevent costly damage in transit

Improve packaging efficiency

Streamline your operations, enhancing efficiency and productivity

Environmentally friendly packaging

Minimise the environmental impact of your packaging and business

Packaging design service

Custom packaging to your exact requirements, designed by an award winning team

Packaging guides and blog

A range of guides, tips and detailed articles to improve your packaging

Case studies

Examples of successful packaging, and how your business can benefit

Packaging markets

Specific industry knowledge and expertise relevant to your business

Quality standards

Accreditations / standards to ensure you get the highest packaging quality

Packaging news at GWP

The latest news, events and community projects happening at GWP Group

Flight Case Foam

Custom Design

Foam inserts, printing and more

UK trade supplier

Tailored pricing on all orders

Case and foam experts

More than 25 years experience

Flight case foam
Foam for flight cases
Custom flight case foam
Large equipment case foam
Road trunk foam

Polyethylene Foam Inserts, Lining & Dividers

Flight case hard foam options for any application

Flight case foam can take a number of forms, all of which can enhance the road trunks / custom built cases used by your business.

From simple foam lining, foam dividers all the way through to fully bespoke foam inserts, there is a suitable option for virtually any application. Manufactured from durable Plastazote® polyethylene foam – which also provides exceptional levels of protection – your low / high density flight case foam can be specified in a number of different colours and grades too. Read More

Available Colours:

Black foam
Grey foam
White foam
Yellow foam
Lime foam
Olive foam
Light blue foam
Blue foam
Purple foam
Pink foam
Red foam
Orange foam
  • No obligation (and no pressure) quotes for any case
  • Impartial advice from UK based experts
  • Competitive pricing and full customisation options


More info on Case Foam

Widely used in broadcasting performance industries, custom built flight cases provide a flexible, cost effective option for the transportation of a wide range of products and equipment.

However, these “road trunks” (as they are often called) can be enhanced considerably with the use of flight case foam.

As with many other forms of foam insert, flight case foam can take a number of forms (all of which can be designed and / or manufactured in house by GWP Protective).

At the most basic end of the scale, lining cases with foam can provide a low-cost way of adding a degree of cushioning protection. This is suitable for big, heavy duty items (such as speakers, small generators etc.) that may suffer minor damage if colliding against the internal walls of the case. Foam lining also has the benefit of protecting the case itself, enhancing longevity.

Foam dividers take this a step further by also securing items within the case (ideal for multiple items or for anything that may be more prone to breaking) and are very efficient in terms of material use. Whilst finally, fully engineered custom case inserts can be tailored to the exact size and shape of the equipment to be stored within the flight case. These can also be used for tool control applications.

Of course, depending on the equipment and the application, a combination of these 3 types of flight case foam can be used, with the foam inserts also being fixed or removable too.

Sourcing flight case foam

Your flight case foam will be manufactured in house by GWP Protective, from Plastazote® material.

Plastazote® not only provides excellent cushioning performance (it is even possible to calculate the exact amount and density required to provide specific protection levels), but a number of other benefits too.

This includes a choice of colours, long lifespan, low odour, being non-absorbent (it is a closed cell material) and being available in a variety of different grades. This final point allows a foam to be chosen to match your specific requirements. For example, high density flight case foam can be used for heavy duty applications.

It is even possible to specify flame retardant or anti-static / conductive foam for your flight case inserts.

Key benefits of custom flight case foam at a glance

  • Low cost foam lined flight cases
  • Foam dividers for item separation within flight cases
  • Fully engineered flight case inserts for highest levels of protection
  • Choice of colours, densities and grade to match your application
  • Custom design service by a team of experts
  • Source flight case and foam together for improved compatibility and performance
  • Prevents transit damage, reducing cost of replacements


Common questions about flight case foam

If you’re looking to buy flight case foam for your business, but have questions you need answering, the below section should help.

However, if you can’t find the answer to your specific question, please contact a GWP adviser who will be happy to help.

What types of flight case foam are there?

Flight case foam can take a number of forms, but this tends to be split into 3 main categories. These are simple lining of the case, foam dividers that hold the contents in place, and fully engineered foam inserts which follow the contours of the specific items to stored / transported (these inserts can be fixed or removable too).

What is flight case foam made from?

Flight case foam will nearly always be manufactured from Plastazote®. This is because it provides excellent levels of cushioning performance (and can even provide very specific, calculated protection), is suitable for most foam conversion processes, has a good appearance and is long lasting and durable.

What is high density flight case foam?

It is possible to get different densities of foam, which can be matched to different applications. Typically, Plastazote® foams (such as LD33 – a commonly used grade) are termed as low density, but an experienced foam engineer / designer will be able to advise on the best option for your specific application.

Can’t I get flight case foam from Amazon?

Whilst it is possible to get flight cases with foam from ecommerce sites such as Amazon and eBay, these can often by cheap imports of low quality. Even if purchasing a UK manufactured case, buying from on online source often means you cannot specify the exact sizes you need (which is the key benefit of using flight cases). Every flight case GWP supplies will be manufactured to your specific size / requirement.

I already have flight cases – can you make foam inserts for them?

It is possible to retrofit foam inserts into flight cases (and indeed any type of protective case – including the EXOCase waterproof flight case), although sourcing both case and foam together from a single supplier can improve the compatibility and fit between case and foam. It is also usually more cost effective to purchase the case and foam together.

I’ve seen flight cases with pick and pluck foam – what is this?

Pick and pluck foam (commonly used as Peli case foam) is a form of foam insert that can be modified by the end user (these are often used alongside egg box, or profile foam). 1cm cubes of foam can be removed individually to eventually create a series of recesses to place equipment into. Whilst these are time consuming to setup, and do not provide as high a level of protection as custom foams, they are a good option for one off requirements.

Free Quotes / Advice

Source flight cases with foam from GWP

GWP Protective are one of the largest B2B suppliers of flight cases and equipment case foam in the UK.

Concentrating on supplying business and industrial customers, you can source protective cases with foam inserts that are tailored to your exact requirements.

And as all the foam we manufacture is fully bespoke to your business, all pricing is as well.

This – and sourcing flight case and foam together – usually means a more cost-effective solution than if you went elsewhere.

Add in free, genuinely impartial advice and no obligation quotes, and it makes it easy for you to source your perfect flight case foam.

Alternative Foam Options

Other foam / case inserts available

One of the key advantages of working with an established foam converter (like GWP Protective) to your business is the range of foam packaging you can source from a single supplier…

Foam case inserts

Case Inserts

Engineered protection for high value tools / equipment

Foam lined case

Lined Cases

Simple lining of cases for cost effective protection

Peli case foam inserts

Peli™ Case Foam

Foam inserts for Peli and all waterproof equipment cases

Tool control shadowboards

Tool Control

Never lose tools or kit again with foam shadow boards

Flightcase foam

All Foam Inserts

See all options for enhancing protective cases

Ethafoam packaging inserts

All Foam Options

Over 25 years experience in foam conversion

External case Options

Wide range of protective cases for any application

Custom flight cases

Flight Cases

Flight cases custom built to your exact specification

Sample presentation foam

Plastic Cases

Perfect for presentation in sales meetings / pitches

Aluminium cases

Aluminium Cases

UK distributors of Zarges aluminium cases range


Waterproof Cases

Widest range of waterproof cases from a UK supplier

Correx totes

Tote Containers

Handling solutions for supply chain / manufacturing

All protective cases

Protective Cases

Huge range of branded or custom equipment cases

Quotes, Technical Info, Advice...

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    Here to Help

    Contact a member of our sales & support team directly

    Dan Wellings

    Dan Wellings

    Product Adviser
    01722 416 440

    Richard Coombes

    Richard Coombes

    General Manager
    01722 416 440

    Ian Heskins

    Ian Heskins

    Sales Director
    01793 754 444

    Phone GWP Protective

    01722 416 440

    Mon – Fri 08.30 – 17.00

    Email GWP Protective

    Email a case / foam expert

    If your business uses flight case foam (or other types of insert) see how GWP can help...