Frequently Asked Questions

Design your foam right in our online builder: 1) Choose your case from our catalog or enter custom dimensions. 2) Add your items — use AI Scan to detect them from a photo, upload a 3D model, drop in simple shapes, or pick from our item library. 3) Drag, rotate, and arrange everything on the canvas, add finger pulls, and preview it in 3D. 4) Check out with a small deposit — we review your design, send you a final proof to approve, then CNC-cut your foam and ship it to your door.

Nope. The photo-based AI Scan is just one way to add items. You can also add rectangles, circles, and ovals with exact dimensions, upload a 3D model (STL or OBJ) of an item, or choose pre-made shapes from our library. Mix and match all of them in the same layout.

Lay your gear flat on a contrasting background (dark items on a light surface or vice versa), include a reference object like a credit card or ruler for scale, and shoot from directly above in good light. The AI detects each item and creates precise outlines, which drop straight into your builder layout.

Our AI achieves 99.8% accuracy on item detection. You can always adjust outlines, resize items, or replace a detected shape with a custom one in the builder before ordering. Plus, every order gets a human review — we send you a final proof to approve before we cut.

Absolutely! Just select your case model from our catalog or enter custom interior dimensions in the builder. We support Pelican, Nanuk, SKB, Plano, Apache, Seahorse, HPRC, Explorer, and many more brands.

The builder is a full design canvas: drag items to position them, rotate and flip them on their side, duplicate or combine shapes, set a custom cutout depth per item, and add circle or tube finger pulls for easy removal. There's a snap-to-grid for precise 1/8" alignment, an auto-arrange button, and a 3D preview so you can see exactly how the foam will look in your case.

Yes. If you have an STL or OBJ file of your gear, upload it in the builder and we'll automatically generate a top-down outline at the correct size — great for 3D-printed tools, custom parts, or anything you already have modeled.

The library has ready-made outlines for common gear so you don't have to scan or measure everything yourself. You can also save your own items and full builds to reuse in future designs.

Yes, create a free account to save unlimited builds. You can come back anytime to load a saved build, keep editing, and order when you're ready.

The builder tracks your foam capacity as you design and won't let you check out until every item fits within the usable foam area — so if you can reach checkout, your layout fits.

We use high-density polyethylene (HDPE) foam, the same material used by premium case manufacturers. It's durable, water-resistant, and provides excellent protection for your gear.

You can customize the depth for each item. Standard foam is 2 inches thick, but we offer various thicknesses. For items that need more depth, we can create multi-layer foam sets.

We offer charcoal gray (standard), black, and orange foam. Custom colors may be available for bulk orders - contact us for details.

Our CNC machines achieve +/- 0.1 inch tolerance, ensuring your gear fits snugly without being too tight. We also add a small clearance (configurable) for easy insertion and removal.

Pricing depends on the foam size, and simple designs start around $49. You'll see the exact price in the builder before checkout — it updates live as you design. The builder itself, including AI Scan, is completely free to use.

You pay a small deposit at checkout to submit your design. We review it and send you a final proof for approval. Once you approve, you pay the remaining balance and we start cutting. If we find an issue with your design during review, we'll work it out with you before anything is cut.

Yes! You can build layouts, run AI scans, upload 3D models, and experiment as much as you want at no cost. You only pay when you order the physical foam.

Yes, we offer discounts for orders of 5+ units. Contact our sales team for custom quotes on large orders.

After you approve your final proof, we CNC-cut your foam and ship it — typically within 5-7 business days, plus transit time. You'll get tracking as soon as your order ships.

Currently we ship within the United States. International shipping is coming soon - sign up for our newsletter to be notified.

We guarantee a perfect fit. If there's an issue with your foam due to our manufacturing, we'll remake it for free. Contact us within 30 days of delivery.

Due to the custom nature of our products, we cannot accept returns for buyer's remorse. However, we'll replace any foam that has manufacturing defects at no cost.

We support all major brands including Pelican, Nanuk, SKB, Plano, Apache (Harbor Freight), Seahorse, HPRC, Explorer, Condition 1, Eylar, and more. You can also enter custom dimensions for any case.

Yes! Enter your case's interior dimensions (length, width, depth) and we'll create foam to fit. This works for any rectangular case.

Yes! Browse our shop for protective cases from brands like Pelican, Nanuk, and SKB. Every case in the shop has a "Build with this case" option that opens the builder pre-loaded with that case's dimensions, so your foam and case arrive as a perfect match.