Pelican cases are trusted across industries for their durability and environmental protection. They are used to transport and store tools, devices, and critical equipment in demanding environments.
While the outer case provides rugged protection, the foam inside plays a major role in how well the case performs day to day.
Pelican case custom foam helps keep equipment secure, organized, and easy to access. Whether you are building a tool kit, transporting sensitive electronics, or preparing a case for field use, the right foam insert makes a meaningful difference.
This guide explains how custom foam works, what options are available, and how to choose the right solution for your Pelican case.
What Is Pelican Case Custom Foam?
Pelican case custom foam is foam that is designed and cut to match the specific items stored inside the case. Instead of a generic layout, each cavity is shaped to support the size, weight, and geometry of your equipment.
Custom foam inserts are commonly used when:
- Equipment has defined dimensions
- Items need to stay in fixed positions
- Cases are deployed repeatedly or across teams
- Organization and consistency are important
At C.H. Ellis, custom foam is engineered as part of a complete case system, not as a standalone insert.
Why Foam Matters in a Pelican Case
The foam inside a Pelican case does more than fill empty space. It directly affects how equipment is protected and how efficiently the case is used.
Well designed foam helps:
- Prevent equipment from shifting during transport
- Protect sensitive components from contact and wear
- Organize tools and accessories clearly
- Make setup and repacking faster in the field
Foam selection and layout are just as important as choosing the right case size.
Foam Options for Pelican Cases
Pelican cases can be configured with different foam options depending on the application and stage of use.
Pick and Pluck Foam
Pick and pluck foam is a flexible and widely used option that allows users to configure layouts themselves.
Key characteristics include:
- Pre scored foam sections that can be removed by hand
- Quick setup without specialized tools
- Easy to adjust as equipment changes
- Suitable for general purpose and evolving kits
Pick-and-pluck foam is a practical solution for many applications and is available through C.H. Ellis, often offering a lower unit cost once the design is optimized.
Custom Cut Foam Inserts
Pelican case custom foam is designed when layouts need to be more defined and repeatable.
Custom foam offers:
- Precision cut cavities matched to exact equipment
- Consistent layouts across multiple cases
- Clear organization and professional appearance
- Long term durability for repeated use
This option is commonly selected for standardized kits, production programs, and professional deployments.
Using Both Foam Types
Many customers use both pick and pluck foam and custom foam depending on their needs.
Common approaches include:
- Pick and pluck foam for adaptable or early stage setups
- Custom foam for finalized equipment kits
- Different foam solutions for different teams or applications
Choosing the right foam is about matching the solution to how the case will be used.
Common Foam Materials Used in Pelican Case Custom Foam
Foam material selection is based on the equipment being protected and the environment it will be used in.
Polyethylene and Cross-Linked (PE) Foam
- Dense, durable, and water-resistant, making it ideal for heavy-duty and industrial equipment.
- Its closed-cell structure holds shape under repeated use, preventing tools and parts from shifting even after years of wear.
Polyurethane (PU) Foam
- Softer and more flexible than polyethylene, making it better suited for lightweight and delicate items.
- Its open-cell structure provides excellent cushioning against vibration and small impacts — critical for protecting sensitive electronics during transport.
Anti-Static and Conductive Foam
- Protects electronic components from static discharge, which can silently damage or destroy sensitive circuits.
- Essential for technology, aerospace, and defense applications where even a minor electrostatic shock can cause costly failures or downtime.
Medical-Grade & Sanitary Foams
- Non-toxic, easy to clean, and resistant to bacteria — designed to meet strict hygiene standards.
- These foams prevent contamination, extend the safe use of equipment, and reduce the risk of costly failures in sterile environments.
Laminated or Multicolored Foam
- Built with layers of different foam densities, providing both firm support and soft cushioning where it’s needed most. This combination protects equipment from a wider range of impacts than a single-density foam.
- Multi-color inlays also create an eye-catching presentation, making cases double as branded displays or organized layouts that highlight every component.
Material selection plays a key role in long term performance.
Foam Layout Options for Pelican Cases
Foam inserts can be designed in different layouts depending on the size and complexity of the kit. Here are a few foam layouts that you may benefit from:
Single Layer Foam Inserts
- All equipment stored on one level
- Simple and easy to access
- Works well for compact kits
Multi Layer Foam Inserts
- Equipment organized across multiple depths
- Heavier items placed in lower layers
- Smaller or frequently used items placed on top
- Maximizes interior space
Display and Presentation Foam
- Clean, high visibility layouts
- Often uses layered or colored foam
- Common for demos, sales kits, and trade shows
Layout design affects both protection and usability.
How Custom Foam Is Designed for Pelican Cases
The custom foam design process starts with understanding how the case will be used.
Key design considerations include:
- Equipment dimensions and weight
- Frequency of use and transport
- Access needs and handling
- Future changes or expansions
Foam cutouts may include finger pulls or visual outlines to make removal easier and improve organization. At C.H. Ellis, foam design is handled in house and tailored to each application.
When to Choose Pelican Case Custom Foam
Custom foam is often the right choice when:
- Equipment is valuable or sensitive
- Layout consistency matters across multiple cases
- Missing items create downtime or risk
- The case is part of a professional or customer facing system
Custom foam helps ensure that the case performs reliably over time.
Working with C.H. Ellis for Pelican Case Custom Foam
Pelican cases are built for demanding environments. The foam inside the case determines how well the system protects, organizes, and supports the equipment it carries. Whether you need adaptable pick and pluck foam or precision cut custom inserts, the right foam helps your Pelican case work the way it should.
As an authorized Pelican distributor and custom foam manufacturer, C.H. Ellis helps customers get more value from their cases.
We support:
- Pick and pluck foam
- Fully custom cut foam inserts
- Short runs and large production programs
- Foam updates as equipment evolves
With over 100 years of experience in case and foam solutions, we help design systems that protect equipment and support real world use. Contact us today to build your custom foam insert