Laser-cut foam inlays — custom inserts for tool cases, transport boxes and presentation cases.

For tool manufacturers, trade fair builders and technical sales organisations, the focus is on custom foam inlays that securely fix components, present them professionally and can be produced economically without stamping tools from a single piece. CAESS Laser cuts inserts from PE foam, EVA, cellular rubber and soft foam precisely according to component contour, CAD data or submitted sample — reproducible up to series.

Inlays that deliver — cleanly cut, exactly fitting

The key is the difference between a stamped standard foam and a laser-precise inlay according to component contour — in fit, protective effect and perceived product quality. A tool case with a clean inlay communicates order, professionalism and quality — before the first tool is picked up. The CO2 laser cuts any contour directly from the file, without tooling lead time and without minimum quantity.

Tools & Industry

Tool case inlays with exact component contour and secure fixation

In the tool sector, the inlay is not decoration but function: each tool lies in its own recess, cannot slip, is immediately findable and can be checked at a glance for completeness when the case is opened. CAESS Laser cuts recesses according to component contour from PE foam or EVA — with clean edges, tight fit and multi-layer constructions for different gripping depths.

Individual tools, sets and assortment boxes
Multi-layer constructions for different component depths
Shadow board principle for quick completeness check

Transport & Protection

Shock-absorbing inserts for measuring cases, camera cases and technical transport containers

Sensitive measuring instruments, optical instruments, electronic assemblies and prototypes need more than loose foam during transport. A custom insert from PE foam or cellular rubber fixes the component on all sides, absorbs vibrations and prevents parts from hitting each other.

Measuring cases for precision instruments and calibration equipment
Camera cases and optical systems
Prototype and sample transport for development and sales

Trade fair & Sales

Presentation cases and trade fair displays with inlay as a sales argument

In sales meetings and at trade fair stands, the moment of opening is decisive. A cleanly cut inlay that presents product samples, material samples or components neatly and attractively creates an immediate quality impression. For trade fair builders, the inlay is a recurring order item with archived data for reorders.

Product samples and material libraries for the field sales case
Trade fair displays with ordered components and logo cut-outs
Reorders for follow-up trade fairs with archived cutting data

What matters technically in this application

Fit determines protective effect and appearance

An inlay that is too large lets the component slip. One that is too tight is hard to remove. Laser cutting works with ±0.1 mm cutting tolerance and follows the component contour directly from the CAD file or submitted sample — the result fits at the first attempt.

Material choice determines protection class and feel

PE foam is robust, dimensionally stable and lightweight — the first choice for tool cases with mechanical stress. EVA foam offers better damping for lighter components. Cellular rubber is closed-cell and moisture-resistant. Soft foam (PU) is ideal for particularly sensitive surfaces.

Scalable from prototype to trade fair series

An individual inlay for the first prototype requires no tooling lead time. The same cutting data later runs for a series of twenty cases at identical quality. For trade fair builders fitting cases for multiple client projects, this is a direct capacity and planning advantage.

Let us align component contour, material and case format for your inlay directly.

If CAD data, a component to be submitted, an existing case or simply a clear idea of the required insert is already available, technical feasibility and the fastest path to the finished inlay can be assessed immediately. Tool manufacturers, trade fair builders and sales organisations are equally welcome. Enquiries are typically answered within 24 hours.