1📦Add your gearPick from 7,000+ items in the Gear Library — or scan yours with your camera.
2✥Arrange itDrag to move, pull the corners to resize — or type exact sizes.
3🛒We cut it exactlyAdd to cart and your foam is CNC-cut to your layout, edge to edge.
Takes about 2 minutes · your work saves automatically
Review your order
✓
Added to your cart
Your custom foam is in the cart.
Approve your design
Cut to your measurements: The inside of your case base, as you entered it. Wrong? (this clears your layout).
What happens next
We CNC-cut this exact layout into your foam — every pocket sized to your gear.
Ships in 7 business days.
Custom-cut foam is made to order and final sale — no returns or exchanges, so check your layout and sizes carefully.
You pay —
⚠ Your design has warnings — check "Before you order" in the left panel first.
Custom CNC-cut foam
CNC-cut exactly to your layout · ships in 7 business days
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Total—
Cut files written
Ref — the same six files an order produces, listed in the orders console under "Internal exports" (kept 90 days).
Which case is this foam for?
Design your own custom foam. Pick your case, add your gear at its real size, and we CNC-cut the foam to fit. Ships in 7 business days.
Measure the inside of your case
Measure where the foam sits: the inside length, width and depth of the base, not the lid and not the outside. We cut the insert to exactly the numbers you enter.
How to measure (4 steps)
Take out any foam that is in the case.
Measure the floor of the base wall to wall, at both ends. If the two readings differ, use the smaller one.
Depth is from the floor to the top edge of the base, not up into the lid.
Enter inches to the nearest 1/16" (0.06). If the floor has rounded corners or the walls lean inward, take 1/8" off the length and width so the insert drops in.
Units
Optional. Match the rounded corners of your case floor so the insert drops in. Auto is a small radius (about 1/4 to 3/4 in). Square is 0.
Custom-cut foam is made to order and is a final sale.
Upload your finished foam file
Keep 0.4" between cuts, 3/4" to the edge. There must be at least 0.4" (10 mm) of foam between every cut and the next one, and at least 3/4" (19 mm) between every cut and the edge of the foam. Thinner walls can tear, so check this in your file before you upload. This is a warning only: you can still upload and order a file that does not meet it.
Upload one file of your finished foam insert and we set everything up from it: the foam's outer size and corner radius, and every pocket and through-cut at its exact spot and depth.
.STL3D model of the foam insert. Binary or ASCII, up to 25 MB. We read the outer size, the pockets and how deep each one goes straight from the shape.
.DXF2D drawing of the foam. Up to 4 MB, closed shapes only. Put the foam edge on a layer named OUTER, partial pockets on layers named like POCKET_1.00IN (the depth), and through-cuts on THROUGH.
Other file types (STEP, IGES, OBJ, 3MF, PDF, SVG, Illustrator) are not accepted here. To add a single gear item from SVG, AI, DXF or STL, use Upload a file in the left toolbar instead. Your file is read in your browser; when you press Use this cut, a copy is kept with your order so the foam is cut to exactly that file.
How to export, and a sample file
SolidWorks: File → Save As → STL. Fusion 360: right-click the body → Save as Mesh → STL (binary). Onshape: right-click the part → Export → STL. FreeCAD: select the body → File → Export → STL.
STL: export the finished foam insert as one solid body, lying flat with the cavities facing up (we also detect a file that is upside down).
Choose millimeters or inches on export. STL files do not store units, so you can correct them after the upload.
DXF: set the drawing units, then use closed polylines, circles or splines on the layers above. Anything on another layer inside the outline is read as a through-cut.
Reading your file… large files can take a few seconds.
Drag a cut in the top view to move it, or click it and use the arrow keys (Shift = bigger steps).
The inside depth of your case base. Leave it blank if you do not know it: we use the foam thickness plus the lid-foam allowance.
STL files carry no units. If the size looks wrong, change the units, which face is up, or which way the cavities face.
Custom-cut foam is made to order and is a final sale.
Gear Library
True-size outlines that drop straight onto your foam
Quick check before you order
Paste SVG code
Illustrator: turn on Preferences › Clipboard Handling › Include SVG Code, then copy and paste again. Or paste the SVG code here.
Scan an item
For automatic exact sizing: lay a credit card (any standard card) flat next to your item —
small gap between them — and shoot straight down. The card's known size measures your item exactly.
No card? We trace the shape and you type the real length.
Starting camera…
Tap the two opposite (diagonal) corners of your card — any credit,
debit, ID or gift card (they're all exactly the same size). Tap a dot again to drag and fine-tune.
Using a tape measure or ruler instead? Tap two of its marks and type the distance between them below.
The card must be in the same photo, lying flat next to your item.
Tracing your item…
Finding the exact shape in your photo. This takes a few seconds.
Outline your item by hand.
Tap around the edge of your item, all the way around (more taps = smoother). Then type its real length end-to-end.
This works on any surface and gives the true shape.
Add at least 3 points around your item, and enter its length.
Sends a small picture of just the item, with the background removed, to our AI so we can look up its exact size. We don’t save the picture.
Units
Type a correction if a dimension is off — the outline rescales to match, so the cut stays true.
Share your design
This link opens your layout on any device — start on your phone, finish on your desktop, or send it to a friend.
Email it to yourself
We'll send the link now and one reminder if you don't finish — nothing else, no list.