Why Case Makers Should Be Cutting Foam In-House With a CNC Router

High-density foam inserts are essential in professional case making. They provide precise, protective housing for tools, electronics, medical equipment, and specialist gear. But many case makers still outsource this part of the process, or rely on manual methods that limit precision and slow production.

Tekcel systems make it easy to bring foam cutting in-house. You can speed up production, improve consistency and reduce reliance on external suppliers. And there’s no need for a dedicated foam-cutting machine.

Why Outsourcing Foam Inserts Slows You Down

Many case makers manufacture the external shell, the carcass, but outsource the foam insert. This is often because foam cutting is seen as specialist work or is just too fiddly to handle.

But insert fit can be inconsistent, especially when relying on external drawings or templating. Reworks slow down delivery. Minimum order quantities add pressure. For businesses offering short-run or bespoke case builds, outsourcing becomes a limitation - not a solution.

The Hidden Cost of Manual Foam Cutting

Manual cutting may seem flexible, but it rarely delivers consistency. Hot wire tools, scalpels or bandsaws all rely on operator skill and time. Clean edges are hard to achieve, and repeated jobs are almost impossible to duplicate perfectly.

You also lose digital control. It becomes difficult to nest parts efficiently, manage offcuts, run repeat jobs or build layered inserts with varying depths. Any adjustment requires starting over.

Why a Tekcel CNC Router Works for Foam

Tekcel routers are the professional go-to for cutting demanding materials like aluminium, acrylic and hardwoods. They deliver the same clean, repeatable quality when machining high-density foams like Plastazote, PE or PU, with minimal drag. Laminated or rubber-backed foams, often used in high-impact applications, can be cut cleanly in single or multiple passes.

Because the same machine can switch from routing MDF to cutting foam, there's no need for separate equipment. One tool change and a vacuum hold-down system are all you need to move between materials.

Complete CNC | Why a Tekcel CNC Router Works for Foam

Key Applications in Case Making

Tool and Equipment Cases
From hand tools to diagnostic devices, Tekcel routers make it easy to create custom-fit cavities that hold each item securely. Profiles can be pulled from CAD or created by scanning the object, then laid out and cut directly into foam. Complex layouts like layered drawers or branded cut-outs are handled with ease.

Medical and Specialist Equipment
When accuracy and hygiene matter, so does the foam insert. Tekcel routers allow you to machine medical-grade foams with consistent depth and edge quality. Inserts for delicate instruments, calibration tools or sterilised kits can be created with far greater reliability than manual processes allow.

Broadcast and Photography
Cases for cameras, lenses, drones or lighting rigs often require both protection and presentation. Tekcel routers enable high-definition cuts for these custom inserts, even when working with multiple foam densities or layered structures. In these industries, protection matters. But presentation matters just as much.

Aerospace and Defence
In industries where traceability, precision and repeatability are critical, CNC machining becomes essential. Tekcel routers offer the control needed to meet specifications for military or aerospace-grade foam. Cut records can be stored, templates reused, and production standardised across teams or locations.

Complete CNC | Key Applications in Case Making

Final Thoughts

Foam inserts shouldn't hold your business back. They should be part of your competitive edge. With a Tekcel CNC router, you can keep full control over quality, lead times and customisation, without outsourcing or second-guessing results.

From cutting case carcasses to producing high-density foam inserts, Tekcel machines power your entire production process from start to finish. The flexibility to handle diverse materials and workflows in-house means you can respond faster, deliver smarter and take on more ambitious projects with confidence.

Ready to put foam cutting on your own terms? Contact Us to explore the best setup for your business.
Call us now to schedule training or learn more about our services! +44 (0) 1934 742186