Custom Foam Inserts

Custom Foam Inserts for any Foam Project

custom foam inserts from Wilson Case

Custom Foam Inserts

Wilson Case Waterjet Inserts

Waterjet, CNC Router &
CNC Knife Cutter

The pros at Wilson Case offer custom foam inserts for any requirement, any size.  Whether it is for your Wilson case, an existing case, or is a part of your product packaging, we can deliver a high quality foam insert at a competitive price and great lead time.  We use the highest quality foam and offer a variety of foam options including ester, etha, anti-stat, crosslink, PSA and flame retardant.  Our design engineers use solid modeling technology and CNC tools to design the insert for a precise fit and ultimate protection.  We offer waterjet, CNC router and knife foam cutting capabilities all from our main production facility. We can custom cut foam for any application no matter the size or quantity.


We offer custom inserts for one-offs as well as large runs. Our flexible scheduling and ability to meet most lead times set us apart.  We promise to protect your product and make you look good!


Computer Controlled Routing (CNC)
CNC routing is a process which uses computer guided drill and router bits for cutting and shaping of many materials. Utilizing CNC routing gives us the ability to design, prototype, and run the production of your project. We can work with substrates such as foams, plastics, and aluminum to machine custom precision parts in small quantities without the expense of tooling.

CNC routing is very useful when fabricating inserts for protective case and other specialty packaging applications as the routing heads can easily fabricate multiple cavity depths.


Water Jet Cutting
Our water-jet cutting is capable of slicing into any type of open cell and closed cell foam using a jet stream of water which is forced through a tiny nozzle at a high pressure of 60,000 PSI to perform precision cutting and leaving smooth, extremely accurate edges.

Our water-jet service is available to any customer for any application.  This is an environmentally-friendly solution for nearly all cutting needs and is less expensive then laser and die cutting.


Custom Foam Insert Gallery