1. Gear analysis
Every custom foam interior begins with a full assessment of your equipment and its operational environment. We define critical parameters such as weight distribution, drop sensitivity, vibration exposure and deployment conditions. Whether your setup is tactical, industrial, stage-ready or camera-based, we classify its protection needs with precision to determine the exact performance level required.
2. Digital capture
Once specifications are confirmed, we translate your gear into a precise digital model. You can provide STEP files directly, or our engineers will use high-resolution 3D scanning to create a flawless replica. Any inconsistencies are corrected in our in-house system to ensure true-to-form modeling from the start. On-site scanning is available for oversized or sensitive assets.
3. Material engineering
Based on your protection classification, we select the optimal foam density and material composition to absorb impact, withstand compression and support long-term durability. From lightweight polyethylene for agile transport to rugged polyurethane for heavy-duty deployment, each material is validated for shock absorption, structural integrity and wear resistance under repeated use.
4. Layout precision design
With all dimensions digitally secured, our engineers create a production-ready layout that positions each component for maximum stability, intuitive access and zero movement during transport. Every insert is modeled under real-world load conditions to confirm alignment, clearance and pressure points before moving toward prototype validation.
5. Prototype validation
Before committing to full production, we manufacture a working prototype to physically verify fit, retention force, handling comfort and shock response. Every contour, cut depth and grip angle is tested under simulated transport conditions. If refinements are needed, they are engineered with surgical precision until the insert meets operational readiness standards.
6. Full-scale manufacturing
Once approved, the design is transferred to high-accuracy CNC production. Each foam layer is cut, bonded and integrated with exact tolerances, ensuring repeatable performance across all units. The final assembly is executed under controlled conditions to guarantee consistent retention, durability and long-term structural stability in every case delivered.
7. Assembly integration
After manufacturing, the foam insert is integrated into the selected case with full verification of fit, compression behavior and structural bonding. Each cavity is checked for precise alignment, load stability and quick-access functionality to ensure the gear is secured for transport without movement or stress deformation.
8. Deployment-ready delivery
Your case leaves our facility fully assembled, tested and certified for operational use. Whether it’s heading to a stage, runway, training ground or tactical zone, every custom interior is built to perform under pressure, protect under impact and deliver absolute confidence from the first mission onward.
9. Endurance verification
Post-assembly, each approved configuration may undergo performance verification under shock, vibration and endurance simulations based on the application class. This ensures long-term retention, foam memory recovery and full operational reliability, even after repeated deployment cycles. Every verified setup aligns with SKB’s durability standards used across defense, industrial and touring applications.
10. Lifecycle support
Once deployed, our team remains available for performance reviews, replacement inserts, expansion sets or reconfiguration for evolving gear requirements. The result is a long-term protection solution that adapts to your mission demands over time rather than ending at delivery. Built once, trusted continuously.
Start the Process
Custom Foam Protection Starts Here
Define your equipment. Specify the mission. Our engineers will begin configuring a precision-fit interior built for impact, stability and operational reliability.