At FUSH Cases, we are committed to helping our clients create the perfect case to protect components during travel or storage. Whether you are an individual looking to safely transport precious cargo, a corporation needing a series of sales kits, or a business desiring to design a case to house a collection of products, our team of experienced foam fabricators will craft a custom insert that will cushion and protect your items.

We recently completed a project for a company that sells products for the natural gas distribution industry. Each product plays an integral part in very technical operations related to this sensitive, naturally occurring substance. So, it is important that these products be safeguarded when they are carried from job to job. The client needed three different field kits, each one comprised of products required for specific undertakings. It was important that the case afford space for all of the key products and that each item was easily accessible.

This project, in essence, was three separate projects. So, we were tasked with developing three unique designs for three different field kits. In addition, each kit contained products in a variety of shapes and sizes. And given the sensitivity of the components, it was extremely important that everything was safely secured. So we had our work cut out for us – but our experienced team was up for the challenge.

Field Kit 1 Case Components

Field Kit 2 Case Components

Field Kit 3 Case Components

We tackled the project one kit at a time. Due to the size of some of the products, many items uncharacteristically needed to extend above the surface of the base foam.  We determined that the depth of the lid could accommodate for this space. This, however, required not only fabricating the base foam, but foam for the lid as well. Having the components in hand allowed us to design inserts that effectively utilized the space of the case, while maintaining adequate cushioning for all items. To accomplish this, the lid was fabricated with different foam thicknesses at different locations to adequately secure the items in the base foam when closing the lid of the case.

The case insert was constructed of 2.2 black polyethylene foam, precisely cut with a water jet cutting machine.

Custom Cut Foam Insert for Field Kit 1 Case Components

Custom Cut Foam Insert for Field Kit 2 Case Components

Custom Cut Foam Insert for Field Kit 3 Case Components

See more samples of our custom foam inserts.

If you need a custom foam case insert, give us a call. As a full-service foam fabricator, our facility is always fully stocked with foam in a variety of densities and composition – so we can ensure short lead times.