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Peli™ Case Foam Inserts

Custom Design

Foam inserts, printing and more

UK trade supplier

Tailored pricing on all orders

Case and foam experts

More than 25 years experience

Peli Case foam
Pick and pluck foam
Peli Storm case foam inserts
Peli foam inserts
Custom Peli case foam
Peli case with foam

Custom Foam for Peli™ Cases

Enhanced protection and ease of use for businesses

Whilst the standard Pick N Pluck™ foam inserts for Peli™ cases are a good option for hobbyists and individuals, custom Peli™ case foam is the only sensible option for professional business and industrial applications.

With the foam inserts tailored to precisely match the contours of your products, tools or equipment, custom Peli™ case inserts provide the highest levels of protection from shock, impact and mishandling – even for very fragile or highly calibrated items. 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 Peli Case Foam

When most people consider Peli case foam inserts, they tend to think of the Pick and Pluck (i.e. cubed foam) option that comes as a standard option across this leading range of waterproof cases (including Peli rifle cases and the Peli Storm range).

These are a great option for individuals, hobbyists and one – off requirements, and are often used alongside “egg crate” or profile foam in the lid. This is because they are low cost, flexible and easy – if time consuming – to setup. However, they are not suitable for professional business applications.

This is for a number of reasons.

Firstly, the “pockets” that can be created within the cubed foam are not tailored exactly to the shape of the items stored within. This can lead to increased damage for very fragile or specialist / expensive items.

Secondly, custom Peli case inserts can be manufactured using specialist software that calculates the exact density and amount of foam required to provide the optimum level of protection. Many people will incorrectly believe that the more foam used equates to more protection, but this is both false and can prove costly in terms of material.

And finally, for business or industrial applications – such as sending high value parts or service engineer equipment cases – the time taken to modify numerous cubed foam inserts would be extremely impractical (especially when using a large case).

So, in essence, custom Peli case foam will provide higher (and customised) levels of protection, will save time, be repeatable, and therefore be more suitable for business applications.

Additional Peli case foam options

Using custom foam for your Peli case inserts also means your business has a number of other options to choose from.

For example, you can choose various coloured foams to match your branding, or to differentiate between different sets of tools / equipment etc.

Using layers of foam can also create a shadow board effect (for tool control purposes). Not only does this enhance the overall appearance, but from a practical point of view it also means that it is much easier to identify when a specific tool or part is missing from the case (as the brighter colour below clearly shows when tools are missing).

Part numbers and instructions (plus logos and branding) can also help improve end user productivity and can be added using foam laser etching techniques.

And it is even possible to have removable foam trays within the case, allowing you to maximise the space more effectively.

Key benefits of custom Peli case foam at a glance

  • Enhanced protection compared with pick and pluck foam inserts (cubed foam) and Peli lid organisers
  • Precisely tailored to your tools, products or equipment
  • Ideal fit with Peli Protector, Storm and Micro cases (plus all other waterproof case options)
  • Vastly reduces and in most cases eliminates handling / transit damage to contents
  • Can be designed using specialist software for precise levels of cushioning protection
  • Choice of densities, grades and colours (to match branding)
  • Potential to add logos, branding and instructions with laser etching
  • Source case and foam together for enhanced compatibility and lower costs


Common questions about Peli case foam

Although the section below is designed to answer the most commonly asked questions about Peli Case foam inserts, you can also contact us here at GWP for any further information you may require.

What are pick and pluck foam inserts?

Pick and pluck foam inserts are a type of foam that can be supplied as standard with Peli cases. The foam is provided in sheets but is pre scored in to 1 cm cubed sections. These can then be removed as required to create semi tailored pockets within the foam to place items into.

What is a custom Peli case foam insert?

A custom Peli case foam insert would be designed and manufactured to fit specific parts, products or tools. The recesses would be cut using a technique such as CNC routing or waterjet cutting, allowing for very intricate designs to be achieved.

Which type of foam should I use for Peli cases?

If you are a hobbyist or only require a single case, then pick and pluck foam is much more cost effective. However, if you need higher levels of protection and presentation for more than one or two cases, the custom foam (manufactured from Plastazote® polyethylene foam) is a better option.

Can I have custom coloured foam inserts?

Custom Peli cases inserts can be manufactured in a range of more than 20 colours. These can be layered and combined however to create some very striking visual effects which, as well as improving appearance, can also help improve productivity through easier identification of tools / equipment.

Will Peli case foam be expensive?

Custom foam inserts are more expensive than using pick and pluck foam, due to machining costs and any design times. However, the costs must be looked at as part of a bigger picture. Pick and pluck foam is very time consuming to create just a single case insert. And, the cost savings in terms of preventing damage to what can be very specialist, expensive or fragile tools, products or equipment will far outweigh the cost of the inserts themselves.

Can Peli case foam be used in other types of cases?

All of the custom foam inserts that GWP Protective design and manufacture can be tailored to suit any case. So, if you use any of the Peli alternatives – such as Nanuk, SKB, Explorer etc – then you can source a custom foam case insert for them too. This extends to aluminium, lightweight plastic and custom-built flight case foam too (all of which are available from GWP).

How can you tell the right type of foam to use?

A team of experienced and knowledgeable designers will be able to guide through the process of creating foam inserts. From previous designs they will know which foams work best for which applications, whilst specialist software can also be used to calculate the exact type and amount of foam required for engineered protection levels.

Free Quotes / Advice

Custom Peli case foam for any application

GWP Protective have been supplying the Peli range of waterproof cases for more than 25 years. This means that any Peli case foam you purchase from us will be guaranteed to provide the optimum level of fit, compatibility and protection.

But, being independent, it means that you can benefit from truly impartial advice on the best foam and case combination for your specific application. Whilst Peli are a great choice, they may not always be the most suitable or cost effective for every scenario. We’ll tell you this, rather than simply trying to sell you cases from one specific range.

All of this is coupled with an expert design team, clean and modern foam conversion facility, and free, no obligation quotes on any custom foam inserts your business needs.

Alternative Foam Options

Dividers, inserts, packaging and more

As foam converters for more than 25 years, GWP can supply so much more than just custom Peli case foam. See all foam packaging, dunnage and insert options below.

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

Flightcase foam

Flight Case Foam

Source flight cases and foam together for highest quality

Tool control shadowboards

Tool Control Foam

Never lose tools or kit again with foam shadow boards

Convoluted egg crate 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

Pelican case

Peli Protector

Market leading waterproof equipment cases

Peli Storm cases

Storm Cases

GWP Protectives’ recommended protective cases

Custom flight cases

Flight Cases

Flight cases custom built to your exact specification

Protective cases

Waterproof Cases

Widest range of waterproof cases from a UK supplier

Zarges Eurobox buying guide

Aluminium Cases

Official distributors of Zarges aluminium containers

All protective cases

Protective Cases

Huge range of branded or custom equipment cases

Please note: All trademarks are registered and/or unregistered trademarks of Peli Products, S.L.U., its parent, subsidiaries and/or affiliates.

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    Dan Wellings

    Dan Wellings

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    01722 416 440

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    Richard Coombes

    General Manager
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    Ian Heskins

    Sales Director
    01793 754 444

    Phone GWP Protective

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    Enhance the protection of your important equipment using custom Peli™ Case foam inserts...