Choosing packaging foam sheets for a camera or equipment case starts with the case interior and the kit you actually carry. A useful insert should limit movement, keep lenses and accessories separated, provide support beneath heavier items and still let you remove everything without pulling on vulnerable controls or connectors.
Camera bodies, lenses, monitors, lights and other equipment vary widely in weight and shape, so there is no single foam thickness or grade that can be recommended for every case. Plan the layout around the item, the case and the way the kit travels.
Why fitted foam helps inside equipment cases
A hard case provides the outer structure, while the foam inside helps locate the contents and cushion them away from the shell. Without a planned insert, items can collide with each other or strike hard case walls when the case is carried, placed down or turned onto its side.
Measure the usable case interior first
Measure the internal width, length and depth, not the external case dimensions. Allow for rounded corners, wheel housings, hinges, lid structures, handles and any ribs or fittings that reduce usable space.
If you are replacing an old insert, do not rely on the worn foam alone. Check the actual case because older foam can compress, shrink or have been cut inaccurately. The how to measure foam guide gives a useful general measuring checklist.
Lay out the equipment before cutting
Arrange the equipment on paper or a temporary base before committing to the foam. Group items that are used together, but keep enough material between cavities to maintain support.
Consider the order in which items are removed. Frequently used accessories are easier to reach near the top or edge, while heavy items are often better positioned where the case can support them without making the whole pack awkward to carry.
Which All Foam packaging materials can be considered?
Closed-cell polyethylene foam
Lightweight closed-cell polyethylene has a firm, non-absorbent structure and is suitable for protective case inserts and reusable lining. The firmer closed-cell option provides more rigidity for demanding case and industrial uses.
These materials are useful where a structured cavity is wanted and the insert may be handled repeatedly. The closed-cell polyethylene packaging guide explains the differences in more detail.
Plastazote foam sheets
Plastazote has a smooth, cross-linked closed-cell structure and is available in several colours. It can suit reusable inserts and presentation cases where appearance and organisation matter.
Colour can help distinguish equipment positions, but choose the foam grade for protection first. The Plastazote foam guide covers current colour and thickness choices.
Flat packaging foam
Flat polyurethane packaging foam provides even cushioning and can be used for case bases, lids and protective layers. It can be useful where some controlled compression is wanted around equipment rather than a fully rigid cavity wall.
It is also the high load bearing flexible packaging grade in the current All Foam range, so it is worth comparing where heavier equipment needs support beneath it.
Ethafoam STPE200
Ethafoam STPE200 is a semi-rigid packaging foam used for transit pads, separation layers, crate lining and protective inserts. It can be considered where flexible foam would compress too easily and a supportive semi-rigid layer is required.
Pink anti-static packaging foam
Camera and video kits contain electronics, but that does not mean every case automatically needs pink anti-static foam. Anti-static foam is intended for relevant static-sensitive components and should be chosen according to the equipment's ESD requirements.
If you are packaging exposed electronic components, circuit boards or other known static-sensitive parts, read the anti-static foam guide and check the required protection. Anti-static, dissipative and conductive materials are not interchangeable.
Support camera bodies on robust areas
Avoid making the insert bear directly on control dials, buttons, screens, hot-shoe fittings, cable ports or lens release mechanisms. Support should be spread over stronger areas of the body or the protective cage where one is used.
For cameras with an attached lens, think carefully about whether the lens mount is being asked to carry load. A long, heavy lens may need separate support so transport forces are not concentrated at the connection between body and lens.
When in doubt, follow the equipment manufacturer's transport guidance and remove accessories that are not intended to remain fitted during transit.
Give lenses enough space and access
Lenses are easier to remove if there is finger space around part of the cavity. A perfectly circular cut-out with no access notch can force the user to grip the lens awkwardly or pull on a cap.
Keep enough foam between neighbouring lens cavities so the walls remain stable. Very thin walls can tear or fold, particularly if lenses are removed frequently.
Caps should be fitted where appropriate, and delicate glass should not be allowed to contact the foam directly if the equipment manufacturer specifies another protective arrangement.
Plan the foam under heavy equipment
The base layer is critical because it carries most of the load when the case is upright. The right thickness depends on weight, contact area, foam firmness and the expected handling conditions.
There is no fixed answer such as 25mm or 50mm for every camera case. Use the packaging foam thickness guide to compare the item, journey and available depth.
If the foam compresses until the product is close to the hard shell, there may not be enough cushioning distance. If the foam is extremely firm, check that impacts are not being concentrated into small contact points.
Do not forget the lid
A lid layer can help limit upward movement, but it should not press heavily on vulnerable controls or glass. Close the empty case slowly during the design stage and check how much lid space is genuinely available.
If the lid has ribs, pockets or document holders, include them in the measurement. A thick lid pad can make the case difficult to close even when the base layout fits correctly.
For new case designs, a flat lid layer can provide even contact where appropriate. Do not copy an old profiled insert automatically, especially if the current All Foam range no longer includes the same product.
Keep batteries and small accessories organised
Loose batteries, chargers, memory cards, adapters and cables can become hard objects inside the case. Give them dedicated compartments or suitable small containers so they cannot migrate into camera or lens cavities.
Moisture and outdoor use
Camera cases are often used outdoors, but foam choice alone does not make the complete pack waterproof. Closed-cell materials have a non-absorbent structure and Ethafoam is described as water resistant, yet water can still enter around the case seal, joints, cut-outs or damaged fittings.
Dry equipment before long-term storage and inspect the case for moisture after wet use. Trapped moisture can affect equipment even when the foam itself is relatively resistant to water.
Open-cell polyurethane foam should be kept dry. If it becomes wet, remove the equipment and allow the case and foam to dry appropriately before reuse.
Protect polished and coated surfaces
Dust, sand or metal particles trapped in a foam cavity can mark a camera body, lens barrel or accessory. Keep the insert clean and inspect it before repacking valuable equipment.
If a manufacturer recommends a pouch, bag or wrap between the equipment and the insert, keep using it. Do not assume direct contact with foam is appropriate for every finish, rubber coating or optical component.
Cutting a DIY camera case insert
Straight cuts and simple rectangular cavities can be achievable with careful marking and suitable sharp tools. Complex curves, stepped depths and close-fitting shapes are harder to cut accurately by hand.
The foam cutting guide covers general marking and cutting principles. For unusual dimensions or a custom case insert requirement, send All Foam the internal case size, item dimensions, approximate weight and intended use through the contact page.
Test the case before relying on it
Once the insert is assembled, load the actual equipment and check:
- The case closes without excessive pressure.
- Nothing moves freely when the case changes orientation.
- Heavy items do not bottom out against the shell.
- Lens and body cavities have practical finger access.
- Controls and connectors are not load-bearing contact points.
- Accessories cannot migrate into other compartments.
- Foam walls remain stable when items are removed.
For valuable or professional equipment, a real transport test should reflect the journey you expect the case to face rather than relying only on appearance.
Common camera case foam mistakes
- Measuring the outside of the case instead of the usable interior.
- Packing too many items into one insert.
- Making cavities too tight for safe removal.
- Supporting a long lens only through the camera mount.
- Forgetting the depth taken up by lid fittings.
- Allowing batteries or accessories to move freely.
- Assuming all electronics need the same anti-static foam.
- Treating closed-cell foam as proof that the whole case is waterproof.
- Ignoring dirt or grit in repeatedly used cavities.
Quick answers about camera case foam
What foam is suitable for a camera case insert?
Closed-cell polyethylene and Plastazote are useful structured options for reusable case inserts. Flat packaging foam or Ethafoam STPE200 can suit other support layers depending on the equipment weight, required cushioning and case design.
How thick should foam be under a camera?
There is no universal thickness. Base depth depends on equipment weight, foam firmness, contact area, fragility, journey and the available internal case space.
Should camera case foam touch the lens glass?
Avoid designing an insert that places load on optical glass. Use the equipment's caps and follow the manufacturer's transport guidance, including any recommended pouch or protective layer.
Do camera cases need anti-static foam?
Not automatically. Pink anti-static foam is intended for relevant static-sensitive electronics. Check the ESD requirement for exposed components or specialist equipment rather than assuming every camera case needs it.
Can I cut camera case foam myself?
Simple straight or rectangular cavities can be cut carefully with suitable tools. Complex shapes and stepped depths are harder to achieve accurately, so contact All Foam if the layout is unusual or the equipment is particularly valuable.
