Service · Foam inserts
Custom foam inserts and tool-control foam in LA.
Pelican-case inserts, tool-drawer organization foam, equipment-protection inserts, and product-presentation foam — cut precisely on industrial CO₂ lasers in Downtown LA. NDA-protected work welcome. Trusted by NASA JPL, the U.S. Army, and aerospace/defense suppliers. Standard turnaround 3 to 5 business days, next-business-day rush available.
Tight tolerances, repeat orders, NDAs signed.
Foam inserts are about repeatability. Whether you are protecting a $50k instrument in transit, organizing $200k of tooling in a drawer, or shipping a product run, every piece has to be identical to the one before it. We do single prototypes, qualified production runs of 100+, and yearly contract refills — same dimensions, every time.
What we make.
Pelican & flight-case inserts
Custom protection foam for cameras, medical devices, scientific instruments, optics, and sensitive equipment in transit. Multi-layer with depth zones. Single units to qualified production runs.
Tool-control / shadow foam
Two-color drawer foam for loss prevention. High-visibility base color shows immediately when a tool is missing. Standard for aerospace, defense, manufacturing, and pharmaceutical floors.
Equipment & product presentation
Sales-kit foam, demo-case inserts, jewelry and watch presentation foam, branded retail packaging inserts that show off the product.
Branded packaging inserts
Branded retail box foam — protective + presentation. DTC tech brands, premium beauty, electronics, kitting for high-end consumer goods.
Multi-layer & depth-zone cuts
Multi-piece builds with different depths for tall and short items in the same case. We cut and ship as a stack, you assemble.
Prototype to production
Single prototype to 100+ unit production runs. Same file, same fit, every time. Hold dimensions across batches.
Materials.
EVA foam is the workhorse. Bring your own laser-safe stock if you need a specific density or color.
EVA foam
1/4″, 3/8″, and 1/2″ EVA foam stocked in DTLA. Multi-layer builds available. Sufficient for the vast majority of insert work.
Customer-supplied foam
Bring your own — closed-cell PE, charcoal foam, density-specific stock. Email first to confirm it is laser-safe.
Backing & layer materials
Mat board and chipboard for backing layers and structural support inside larger builds.
How to order.
Send the case dimensions, the tools or product to fit, and your file or photos.
Email americanlaserco@gmail.com with your case interior dimensions, what is going in it (with dimensions or photos placed on a ruler), foam thickness, and quantity. NDA needed first? Mention it in the email — we send ours, or sign yours, before we open the file. Or start on the quote page.
Common questions.
Do you do tool-control / shadow foam?
Yes — two-color builds with high-visibility base color so missing tools are visible immediately. Standard for AS9100, NADCAP, and quality-system environments.
Can you fit my Pelican / Storm / SKB case?
Yes — send us the case model and we will pull the interior dimensions, or send the case for measure.
Do you sign NDAs?
Yes. We sign yours or use a mutual NDA template before we open files. Common for medical devices, defense contractors, and unreleased products.
Can you cut polyurethane foam?
Limited — polyurethane outgases more than EVA when lasered. EVA foam is preferred and is what we keep on hand. Custom orders of laser-safe alternative foams welcome.
What is the minimum order?
One single insert is fine. We also do production runs of 100+ with consistent fit across batches.
What is the turnaround?
Standard orders run 3 to 5 business days. Next-business-day rush available — common when a piece of equipment is shipping out the next day and needs travel protection.
Can I send a photo of my tools?
Yes — place tools on a ruler-marked surface and photograph them straight down. We will vector outlines from the photo for a small file-fixing fee.
Start your foam insert project.
Send the case dimensions and the tools or product and we will quote it.