Custom Foam Inserts for Pelican Cases

Precision-Engineered Protection for Your Pelican Case

Trusted by Small Businesses,
Fortune 500 Companies &
Government Organizations

Why Choose Custom Foam for Your Pelican Case?

Pelican cases are trusted worldwide for their rugged, waterproof protection. But the interior is what determines whether your equipment arrives organized, protected, and deployment-ready.

Rather than relying on universal foam inserts, C.H. Ellis designs custom Pelican case foam around your exact equipment, workflow, and operational requirements. The result is a solution that protects valuable equipment, speeds deployment, and presents a professional, organized appearance.

Common Precision Foam Manufacturing Methods

Every application has different production requirements.
We use multiple fabrication methods to match your project.

waterjet cutting

Ideal for complex geometries and clean, precise cuts without material distortion.

CNC Routing

Delivers highly accurate foam fabrication with repeatable precision for custom inserts and production programs.

Die Cutting

Efficient and cost-effective for high-volume production runs with consistent repeatability.

FOAM MATERIALS

The right foam material depends on your equipment, environment, and protection requirements. C.H. Ellis helps match the right foam type to your specific application for long-term performance and reliability.

Polyethylene foam
(Closed Cell)

A durable, water-resistant foam commonly used for heavier tools and equipment requiring secure positioning and long-term structural integrity.

Polyurethane Foam
(Open Cell)

A softer, impact-absorbing foam ideal for delicate or sensitive equipment that requires cushioning during transport.

Cross-Linked Polyethylene (xlpe)

A premium foam with a smooth, refined appearance and excellent durability. Often used for high-value equipment, presentation cases, and applications requiring a cleaner aesthetic.

Anti-Static Foam

Designed for electronics and sensitive components where static discharge protection is critical.

How Custom Foam Inserts for Pelican Cases Are Made

Every custom foam insert begins with your equipment specifications and ends with a precision-engineered interior built to fit your Pelican case.

Our fabrication process is designed to ensure every insert provides the protection, organization, and repeatability your application requires.

Specification Submission

Whether you have CAD files, engineering drawings, rough dimensions, photos, or just an idea of what you need to protect, our team will help determine the best foam material, density, and fabrication method for your application.

Custom Foam Layout

Our engineers create a custom foam layout that securely positions each component while considering accessibility, protection, and how the equipment will be used in the field. This behavior-driven approach ensures the insert supports both the equipment and the user.

Precision Fabrication

Once approved, your insert is manufactured using the fabrication method best suited to your project. Depending on the design and production volume, we use CNC routing, die cutting, or waterjet cutting to produce clean, repeatable foam inserts with tight tolerances.

Assembly & Delivery

The completed foam insert is fitted into your Pelican case, inspected for quality, and shipped ready for immediate use. Whether you need a prototype or a production run, every insert is manufactured to deliver consistent protection and organization.

Applications for
Custom Pelican Case Foam

Our custom foam inserts are designed for organizations that depend on Pelican cases to protect valuable equipment in demanding environments.

Test & Measurement Equipment

Secure sensitive instruments during transport while maintaining organized layouts for fast deployment.

Medical Devices

Protect diagnostic equipment with precision-fit foam engineered for reliable handling and repeatable organization.

Cameras & Imaging Equipment

Cushion cameras, lenses, and accessories while preventing movement during travel.

Tool Kits & Field Service Equipment

Organize tools and accessories for faster access, improved accountability, and greater efficiency in the field.

Electronics & Communications Equipment

Anti-static foam solutions help protect sensitive electronics from impact and electrostatic discharge.

Why Teams Choose C.H. Ellis

Minimum order quantities and lead times vary based on foam type, fabrication method, and production volume. Our team works with you to recommend the most efficient manufacturing approach for your program.

Authorized Pelican Dealer

Source genuine Pelican cases and custom foam inserts from a single supplier.

In-House Foam Fabrication

Every insert is designed and manufactured by our engineering team for precise fit and repeatable quality.

Behavior-Driven Design

We don’t simply trace equipment. We engineer layouts around how users access, transport, and interact with their equipment.

Production Ready

Supporting prototypes, contract manufacturing, and high-volume procurement programs.

Build a Better Pelican Case System

Protect your equipment with custom foam inserts engineered specifically for your Pelican case and application.

Whether you’re purchasing a single prototype or managing a production program, our team will design the right solution for your equipment and workflow.