Protect Your Products with Custom Cut Foam

At Royal Case, we have spent the last 35 years designing cases and foam – so we know what it takes to ensure your products are fully protected not just on the outside, but on the inside as well. Custom cut foam greatly enhances your product's appeal and adds product longevity for the end user.

We offer several options for foam assembly, including foam on metal or plastic, PSA adhesive and lamination, hot melt or heat bonding, and spray adhesives. We also have a wide selection of foam colors, grades, thicknesses and textures to both compliment, as well as protect, your product’s presentation.

Based on your product, case, application and anticipated external wear, we’ll suggest the best inner protection and application method for your custom foam fabrications.

Foam Capabilities

  • 2 axis CNC contour cutting
  • 3 axis CNC routing
  • Waterjet cutting
  • PSA laminating of foam glued to foam or other materials
  • Die cutting
  • Convoluting
  • Closed cell splitting and slitting
  • Wire cutting
  • Compression, contour, and die cutting
  • Special shape cutting
  • Slitting and skiving
  • High speed rotary, kiss and die cutting

Get a quote on your project now and find out why more people choose Royal Case Company every day for all their case and foam needs.

"We use custom foam to help protect our
sensitive electronics from damage."

- Thomas H.

Give Your Products the Royal Foam Treatment.

Custom foam increases the value of your product offering and protects your customer's investment.


Industry Experience

Partial list includes:

  • Emergency Medical & Response.
  • Sporting Goods & Recreation.
  • Military & Government.
  • Music, Recording, Education.

Thousands of Options

  • Color, thickness, density.
  • PU, PE, EPE.
  • Crosslink, Cellular Rubber.
  • Custom Cut.

Quality & Volume

  • 100k Units Manufactured Daily.
  • 5 New Products Brought to Market Daily.
  • Less than 1% Rejection Rate.
  • Berry & DFARS compliant, ITAR registered.

Why Royal Case?

  • Made in USA or Overseas.
  • Centrally Located in Texas.
  • We Specialize in Quality & Volume.
  • 35 years of Experience.

Enhance the Value of your Products with Custom Cut Foam from Royal Case Company.

Full Service Manufacturing Gets the Job Done Right.

From design to delivery, Royal Case Company manages the entire lifecycle of product development.

CAD Design

A quality product begins with quality design. Our CAD designers will work with your drawings to ensure a custom fit every time using professional tools like AutoCAD and SolidWorks.

Finishing Touches

Our finishing options ensure that your product is uniquely yours. There are many options to choose from and Royal Case will help you choose the best ones to set your product apart from your competition.


We have over 25 years of experience in warehousing, logistics and inventory management with warehouses in the USA, China, Thailand, & the UK. Our just in time ability gives you a competitive advantage.


Get a Free Foam Sample For Review.

Make your request now and we'll get your item in the mail within 24 hours.