CNC foam cutting — how does it work?
1. Measuring and the 3D model
It all starts with the device's dimensions. A physical sample, a technical drawing or a ready 3D file will do. From these we build a digital model of the foam insert, where every pocket, cable channel and finger slot is placed so the device sits snugly and does not move in transit.
2. Choosing the material
Foam density and thickness are chosen to match the contents. Softer foam suits delicate optics and electronics; denser foam suits heavier tools and equipment. Thickness depends on the case depth and the device height — we usually use several layers: a base pad and a cut layer with pockets on top.
3. CNC cutting
The digital model goes to the CNC cutter, which cuts the foam to the model precisely and repeatably. The same result can be reproduced identically on a repeat order — hand cutting cannot guarantee that accuracy or repeatability. Complex shapes, bevels and precise pockets come out clean.
4. Assembly and quality control
The cut layers are placed into the case and we check the fit against the actual device: does it sit firmly, does the lid close without obstruction, does anything rub. If needed we add pull-out tabs, labels or a logo. Only after this check does the case ship.
Need a foam insert for your device?
We make CNC foam inserts, flight cases and logo OEM cases at our factory in Paide; custom orders usually take 2–4 weeks. See the custom order page or send an enquiry.
