Custom protective packaging · Oak Ridge, Tennessee · Since 1991 (865) 481-3801

Custom industrial packaging

Custom injection molded cases.

Hard cases with custom foam.

We supply Pelican, SKB, NANUK and Condition 1 cases nationwide. Our in-house team helps you choose a case, designs and cuts the foam, and keeps the approved design for repeat orders.

Explore custom foam

Free design & quoting. No obligation.

An open medical equipment case with custom foam pockets in the base and lid.

Designed around your equipment

Foam pockets sized for your equipment, with room to grip and remove each item.

Free design and quoting

Review the proposed case, foam layout and price with no obligation to purchase.

Prototypes and repeat orders

We keep your approved design so you can order more cases or update the foam when equipment changes.

Ways to order

Order the case, the foam, or both.

Complete case and foam

We help you choose a case from the brands we carry, design and cut the foam, and add straps or other features to hold items in place.

Case only

We supply cases without custom foam and can often beat online retail pricing. Send us the brand, model, quantity and required date for a quote before you buy online.

Foam for an existing case

Keep your case and replace or update the foam. We make the new insert to fit the space inside, your equipment and the way you pack it.

Explore foam-only options

Brands we carry

Compare four case brands.

Pelican

Our most popular case brand.

We supply the full Pelican case range, including Air, Protector, Storm, Micro and Vault, plus Pelican-Hardigg rotomolded single-lid and rack-mount cases. We can help select the case and build its custom foam interior.

SKB

Our widest range of case options.

SKB makes injection molded, rotomolded, vacuum-formed and rack-mount cases, including iSeries, rSeries, vSeries, TL and FP models. Its range of sizes and configurations gives us more options for finding a close fit for your equipment.

NANUK

Canadian-made cases with distinctive details.

NANUK cases are made in Canada. Their distinctive sizes provide alternatives when other case models do not fit your equipment. Customers also choose them for details such as the PowerClaw latches, which clamp shut and use a slide lock to prevent accidental opening.

Condition 1

Our most affordable case brand.

Condition 1 is the first brand to consider when price is the priority. The range includes small, medium, large, long and wheeled cases. We can help select a model that fits your equipment and add custom foam.

Case selection

How to choose a case.

Closed black transport case standing upright with its telescoping handle extended.
Dimensions and usable space
Check the length and width inside the case, the depth of the base and lid, and the space needed for foam. Make sure it can close with everything inside. Outside dimensions alone do not tell you whether the kit will fit.
Loaded weight and handling
Add the weight of the equipment, foam and case. Choose handles and wheels for how people will move it, and plan lifting equipment if needed.
Environment and required ratings
Tell us about exposure to water, dust and temperature, and how the case will be used. We check required ratings against the specific model and any interior work or changes that could affect them.
Transport and access
Check that the case fits your vehicle and storage space and meets the carrier’s size limits. Consider whether it needs to stack or lock.
One case or several?
Decide what must travel together and what can go in separate cases. A single case keeps the kit together, but several cases may be easier to lift and carry.

Your options

Foam materials and interior options.

The interior should support your equipment and leave space around connectors, fittings and delicate surfaces. We can add these features to fit and organize the complete kit.

Foam materials and cutting

  • PE, PU and XLPE foam

    Choose PE, PU or XLPE foam in available densities and colors. We recommend a material for the weight and cushioning needed, and check the grade against any specified performance requirements.

  • CNC router and CNC waterjet cutting

    We cut foam with CNC routers and CNC waterjets. We choose the method for the foam material, pocket shape and depth, and the number of inserts needed.

    Compare the cutting methods
  • Pockets and layered interiors

    Different pocket shapes, depths and foam layers keep the kit organized. We leave enough foam beneath each item to cushion it and enough room above it to close the case.

Access and organization

  • Finger and hand access

    Finger and hand openings give you room to grip each item without pressing on delicate parts. We place them to suit how you pack and remove the equipment.

  • Trays and separate compartments

    Trays, removable foam layers and dividers separate items used at different times. Cables, chargers, tools and spare parts each have a place, making the kit easier to check and repack.

  • Straps, clips and lid storage

    Straps and clips hold items in place, and lid compartments provide extra storage. We check that items stay secure and the lid can close without pressing on equipment in the base.

See foam materials and fabrication options

Common applications

Cases for technical equipment and working kits.

Cases with custom foam can hold one item or a complete kit. We choose the case and arrange the foam to suit how the equipment travels and how you pack and use it.

Drone, robot and communications kits

Organize airframes, controllers, batteries and support equipment for deployment, with access to the components needed in the field.

Explore drone and communications kits

Deployable technical kits

Use fixed component locations to help teams check kit contents and repack consistently between deployments.

Explore repeatable kit layouts

Our process

Design, prototyping and production.

  1. Send your equipment details

    Send dimensions, drawings, 3D models or samples. We will let you know if we need more information.

  2. Review the design and quote

    Review the case, foam layout, materials and price. Our design team can provide models to help you see how the equipment will fit.

  3. Check fit and approve

    If a physical fit check is needed, we quote a foam-only or complete prototype. Review it with the equipment and approve the final design before production.

  4. Build and plan repeat orders

    We build the approved design and keep it for future orders. Tell us about equipment changes before reordering. We can also discuss holding completed packaging and arranging deliveries around your schedule.

Design and quoting are free. Physical prototypes and production are quoted separately.

Lid foam being installed in a case for the military drone equipment program.

Frequently asked questions

Design, ordering and lead times.

Contact us to discuss product selection, design requirements or an order.

Start with these details:

  • Equipment and accessories, with approximate dimensions and weights.
  • Existing case brand and model, if there is one.
  • How the kit will be carried, shipped, stored and used.
  • Quantity, delivery date, likely repeat orders and changes to the equipment.
  • Any required ratings, material specifications or contract requirements.

Drawings, CAD, photos or samples can help refine the design. Begin with general, non-sensitive information and agree on an appropriate transfer method before sharing restricted files.

Tell us about your project

What do you
need to protect?

Tell us what you need to pack, how it will travel and when you need it. We can help you choose a case, foam insert or wood crate.

  • Free design and quoting
  • Direct access to our team
  • No obligation to purchase
Prefer to talk?(865) 481-3801

Start your project

Provide a general project description. Do not include CUI or export-controlled information.

PDF, images, CAD files, or ZIP. Up to 5 files, 20 MB each. ZIPs may contain up to 20 files, totaling 20 MB when opened. No password-protected or nested ZIPs.

Use non-sensitive sample files only. Do not attach CUI or export-controlled technical data. Contact our team to arrange an approved transfer method.