Foam & Case Inserts

Custom-cut foam inserts and case liners for tools, equipment, samples and fragile products. We cut clean, repeatable profiles for protective packing, tool control and presentation kits — made in Sydney and shipped Australia-wide. Upload your DXF for instant pricing, or send a parts list and measurements if you need help creating cut-ready fill

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Flat parts only — no folding Typical sheet up to 3000 × 1500 mm 1–5 days dispatch
Foam & Case Inserts

What we cut for foam & case inserts

We support manufacturers, service teams, AV and camera crews, trade contractors, and brands with inserts that protect gear, speed up setup, and keep kits consistent across teams and sites.

  • Custom foam case inserts (tools, kits, spares)
    Protective inserts for tools and components.
  • Protective packaging inserts for products and components
    Packaging to ensure safety during transport.
  • Tool-control layers (cut-outs for tools and parts)
    Custom cut-outs to keep tools organized.
  • Presentation box inserts and sample kits
    Foam inserts for product samples and presentations.
  • Camera, drone and electronics foam layouts
    Custom foam layouts for cameras, drones, and electronics.
  • Medical and lab equipment inserts (non-sterile packaging)
    Foam inserts for medical and laboratory equipment.
  • Flight-case and road-case foam liners
    Foam liners for protecting items during transportation.
  • Shadow board foam panels for vehicles and workshops
    Foam panels to organize tools in vehicles and workshops.
  • Divider pads, layer pads and top/bottom cushions
    Foam pads for dividing and cushioning items.
  • Pick-and-pack station inserts and bin liners
    Inserts and liners for efficient packing operations.
  • QA / service kit layouts for repeat deployments
    Foam layouts for quality control and service kits.
  • Replacement foam for existing cases
    Replace old or damaged foam in cases.

Foam materials we cut

We cut a wide range of foams and soft materials for inserts. Share your application (impact protection, tool control, presentation, chemical exposure) and we'll recommend a suitable option.

Material choice depends on use case

EVA & PE foams

  • EVA foam inserts for durable, clean edges.
  • PE foam for lightweight protection and cushioning.
  • Layered foam builds to create depth without machining pockets.
  • Optional finger pulls, slots and label cut-outs.

Best for: tool kits, service cases, presentation packs and general protection.

PU & softer foams

  • Polyurethane (PU) foams for soft cushioning.
  • Higher-compression foams for light shock absorption.
  • Top pads, lid liners and thin protective layers.
  • Custom shapes for irregular products.

Best for: delicate products, protective packing and lid liners.

Liners & specialty sheets

  • Felt and fabric liners (material dependent).
  • Rubber sheets (knife cut).
  • Cardboard templates for packing stations.
  • Thin gasket-style sheets for spacers and separators.

If you're unsure what foam you have, send a photo and thickness and we'll help identify a workable cutting method.

Capabilities at a Glance

Processes for Foam Inserts

  • Digital knife cutting for foam sheets and soft materials
  • CNC router cutting for thicker foam and rigid sheets (material dependent)
  • CO₂ laser cutting for acrylic, templates and fine-detail plastics (where suitable)
  • Layered inserts to create depth and secure fit

Typical Deliverables

  • Bottom insert — cut-outs + finger pulls
  • Top pad / lid liner — protective layer
  • Spacer layers — stacked depth control
  • Repeat kits — consistent packing layouts

Accuracy

  • Foam tolerance depends on foam type, thickness and density
  • For tight "snap" fits, we can test and adjust clearances after a prototype
  • Files are cut at 1:1 scale with clean, closed geometry

Finish

  • Clean cut edges designed to protect products and hands
  • Optional engraving/marking on suitable materials for labels
  • Nesting to minimise waste on premium foam sheets

Sheet Size

We can cut foam sheets and boards up to 1500 mm × 3000 mm. Larger inserts can be split into sections for easier transport and assembly inside the case.

We cut inserts and liners — we do not supply the cases. If you already have a case model, send internal dimensions and we'll fit the insert to suit.

Why teams use us for foam inserts

Fast prototyping (then repeatability)

Foam inserts often need a real-world test for clearance and usability. We can prototype quickly, then lock the layout for repeat orders — perfect for tool kits, service teams, and product shipments.

Layered designs for practical depth

Instead of relying on complex 3D machining, we build depth using stacked foam layers. It’s cost-effective, easy to replace, and works well for many equipment and tool layouts.

Clean, organised kits

The goal is simple: everything has a place. Clear cut-outs and consistent layouts make it easier to spot missing tools, pack quickly and keep kits standard across multiple teams.

Trade-friendly workflow

We work with OEMs, maintenance teams, resellers and packaging partners. Supply your own foam or use ours — either way we’ll deliver parts labelled and packaged so your team can assemble kits without confusion.

Sydney based, national reach

Based in Botany, we ship across Australia. For local clients, you can bring a case and equipment for a quick fit check before rolling into production.

Upload your DXF & get instant pricing

Get instant prices for laser-cut and CNC-cut parts across metals, plastics, composites and more — available 24/7.

1–5 days dispatch Australia-wide delivery Pickup: Botany NSW

Get an instant price

Launch the calculator to upload DXF, DWG or vector files and see live pricing for flat laser-cut parts. Pricing updates instantly based on material, thickness and cut time.

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Accepted formats: DXF / DWG / AI / SVG / PDF (vector).

No CAD? We can help

Send measurements, sketches or existing parts and we’ll create cut-ready drawings, then quote via the same engine.

Request drawing help Email a brief →

Simple plates and brackets can often be drawn and quoted the same day.

More about custom foam & case inserts

A well-designed foam insert protects equipment, speeds up packing, and reduces missing items. Laser Cutting Experts produces custom foam inserts in Sydney using digital knife cutting and CNC cutting so you can go from concept to repeat production without tooling delays.

Many inserts are built from stacked foam layers. Each layer is cut with a specific profile, then bonded or assembled to create depth and support. This approach keeps costs sensible, makes replacement easy, and provides clean, consistent cavities for tools and equipment.

Protection-focused inserts usually prioritise cushioning and impact control, while tool-control inserts prioritise durability and clean cut-outs. Tell us what you are packing and how the case will be used (transport, service calls, freight, storage) and we can recommend a foam type and thickness strategy.

Good foam layouts have finger pulls, sensible spacing, and clear orientation. For tools and spares, consider grouping items by workflow so packing is fast. For fragile products, leave enough foam wall thickness between cavities so the insert stays strong over time.

DXF is ideal for foam cut-outs. AI, SVG and vector PDF also work well for dielines and layouts. Export at 1:1 scale in millimetres, remove duplicate lines, and keep each layer clearly named if you have multiple foam thicknesses.

We can cut foam sheets and boards up to 1500mm x 3000mm. If your insert is larger, we can split it into sections that join cleanly inside the case or crate.

If you already have an existing insert you like, we can replicate it and improve usability (finger pulls, clearer spacing, better nesting) where appropriate. For new kits, we can help you plan a layout that balances protection, speed of use and material efficiency.

Custom foam inserts for cases, kits, products and presentations. Prototype first, then repeat production with consistent results. Cut in Sydney with fast shipping Australia-wide. Send your DXF or brief and we’ll help you get a foam insert that looks professional and works reliably in the field.

FAQ

We supply the inserts and liners only. If you have a case model already, send internal dimensions (or bring it in for a fit check) and we’ll cut the insert to suit.

Yes. We can cut one-off prototypes and small runs. For very complex layouts, we'll usually recommend a prototype first to confirm clearances before running volume.

DXF is best for cut-outs. We also accept AI, SVG and vector PDF. Keep everything at 1:1 scale in millimetres and label layers if you have multiple foam thicknesses.

We can cut foam sheets and boards up to 1500mm x 3000mm. Larger inserts can be split into sections that assemble neatly inside the case or crate.

Yes. Provide internal case dimensions and item dimensions (or a parts list). We can create a cut-ready layout and advise on clearances and layer strategy before cutting.

We cut and ship from Botany in Sydney, supplying customers across Sydney, Melbourne, Brisbane and other major centres. Pickup is available from the workshop for local customers.

Laser Cutting for Foam & Case Inserts in Sydney. Laser Cutting Experts Offers High-Precision Laser Cutting Services for Foam & Case Inserts in Sydney Australia.

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