How to Make Custom Foam Inserts with EVA and a Trim Router!

by Shannon M on December 06, 2023

Hey gear enthusiasts! Your tools, cameras, laptops, and AV gear mean more than just equipment – they're extensions of your passion. Whether you're a photographer, tech aficionado, or AV pro, safeguarding your gear is vital.

But here's the kicker: standard protection just won't cut it. That's where the handy combo of EVA foam and a reliable trim router comes in. In this guide, we're delving into the pleasing realm of crafting personalised foam inserts.

Say goodbye to generic storage solutions and say hello to gear sanctuaries that are as unique as your gear collection. So, gear up for an adventure that's equal parts protection and creative expression. Let's roll!

Ready to embark on your DIY adventure? Watch our video tutorial + let's get started!


Required Tools and Materials

Before we dive into the nitty-gritty of crafting, let's make sure we're well-equipped for the adventure ahead. You'll need a handful of tools:

  1. EVA foam 
  2. Felt tip pen (grab an extra-long one if you're feeling fancy)
  3. Trim router (a cool electric tool)
  4. And, of course, the gear you want to house.

Each tool has its role in this creative process, and we're about to show you just how they work together to protect your gear. For this demonstration, we'll be using the Titan AV 30mm EVA shadow foam

Why EVA foam?

Not all foams are created equal, especially when it comes to safeguarding your gear. EVA foam offers impressive durability that ensures your cherished equipment remains safe and sound. Not only is it impact-resistant, but it's also immune to mould, making it ideal for long-term storage.

Rest easy knowing that EVA foam is non-toxic, non-abrasive, and dust-free, preserving the integrity of your valuable gear.

Why Choose Custom Foam Inserts?

Picture a world where gear never tangles, bumps, or goes missing. Custom foam inserts make this real. They're not just protection – they're sanity savers. Efficient transit, ready setups, and the satisfying order of Marie Kondo. Keep your gear pristine and exactly where it should be inside a custom foam insert.

Planning, Tracing & Marking Your Layout

Imagine a puzzle where every piece fits like magic. Play around with your gear to see how it can snuggle up together. Make sure to leave enough room between objects and check that your foam is deeper than your gear – we're all about snug protection here. Once you've nailed the layout, grab that felt tip pen and trace the outline of your gear. Easy-peasy!

Note: While using double-sided tape to secure the foam onto the surface can be helpful (to ensure your foam doesn't move during carving), it's not a mandatory step.

Rick lays out his equipment atop the foam and prepares to trace
Pro Tip: You can pick up an extra long tip marker for precision tracing.
Empire branded extra long tip marker

Using the Trim Router

Time to get your hands on that trim router. This nifty tool is like a wizard's wand, cutting into foam, plastics, and wood with flair. Say goodbye to the struggles of carving with a regular knife; this bad boy makes clean cuts and saves you the headache.

We recommend employing a trim router with a straight twin-blade bit for crafting custom storage spaces for your tools, cameras, audio gear, and more. Our choice is the Ryobi Trim Router 400W

Rick using the Trim Router to carve out unwanted foam

Use the Trim Router to carve out unwanted foam

Getting the depth of your foam cuts just right is crucial for ensuring a snug fit for your gear. So, before you start routing measure the blade bit's depth against your equipment to ensure an accurate cut.

Position your trim router at a 90-degree angle for clean cuts. Meticulously carve within the traced lines, remembering that it's simpler to remove excess foam than it is to add it back in.

Cutting out unwanted foam using the Trim Router

Test Fitting and Refining

After carving, test the gear fit within the insert. Use the trim router for adjustments until it fits seamlessly. For bulkier gear, craft an extra EVA foam layer. Place the top layer atop a second foam sheet and trace around the deepest section. Use the trim router to achieve the desired fit.

Cut out foam end result

For added convenience, consider incorporating finger grips by placing an Australian 20-cent coin where you'd like to hold your gear and tracing around it.

Get Crafting Today

And there you have it – your very own custom foam insert, crafted using Titan AV's EVA shadow foam. Crafting your own custom foam inserts isn't just about protection – it's about preserving your passion and ensuring that your gear is always ready for action.

By combining the durability of EVA foam, the power of a trim router, and a dash of creativity, you can elevate your gear-storage game to a whole new level. So why wait? Give your valuable equipment the care it deserves with custom foam inserts crafted by you, for you. 

You can pickup one of our EVA foam sheets and create your own custom foam insert. Or if DIY isn't your thing, Titan AV offer custom cut foam solutions...

Titan AV's Custom Foam Inserts

After witnessing the dedication involved in crafting a custom insert, you might be wondering, "Is it worth the effort?" or "Do I have the time?" Well, here at Titan AV, we're more than just gear sellers – we're solution creators.

Titan AV Road Case with EVA Foam Inserts inside Rack Drawer

Our expert team, armed with cutting-edge CNC technology, meticulously engineer custom foam inserts that ensure optimal protection and order for your equipment.

Our Australian Made certification adds authenticity and excellence to the mix. But let's not just talk; let's show you a real-life case study to demonstrate exactly why Titan AV stands out.

Case Study: Custom Foam Insert for VR Gear

Let's dive into a real-life example that showcases the power of custom foam inserts. Imagine you're a firefighter gearing up for high-stakes training scenarios. In this line of work, your Oculus Quest VR headsets play a vital role in simulating hazardous situations. But there's a catch – these headsets come with a bundle of cables and chargers that can easily turn into a tangled mess.

Rick holding a Virtual Reality Headset above its custom made VR case foam insert.

Here's where our custom foam inserts step in as the unsung heroes. Not only do they provide snug protection for your Oculus Quest VR headsets, but they also solve the cable conundrum with a hidden cabling system.

Say goodbye to the frustration of untangling cords. With our solution, you have a dedicated space for each cable and charger, ensuring hassle-free access and organisation.

Above view of custom made VR case foam insert showing the hidden cabling for in case charging.

But wait, there's more. We've thought beyond protection and organisation. Our design includes multiple compartments that cater to the unique needs of VR gear.

Your Oculus Quest VR headsets have their own cozy spots, separate from the cables and chargers. No more rubbing against each other, risking scratches or damage. Our multi-compartment design ensures each piece fits like a puzzle, preventing any possible wear and tear during transport or storage.

And the cherry on top? We've embedded this functionality into a sleek and sturdy foam insert, adding a touch of simplicity and sophistication. Your gear now rests in a safe haven, charged and ready for action whenever you are.


So, whether you're a firefighter responding to virtual emergencies or an AV enthusiast seeking seamless equipment management, our custom foam inserts have got your back.

The Ultimate Gear Solution is Made in Australia

Titan AV foam inserts are designed & cut by our team in Brisbane using CNC router machines, capable of precision cutting various materials like foam, aluminium and plywood. 

A custom made CNC machine cut creation by Titan AV holding moving head lights.

We craft solutions with your challenges in mind, addressing cable chaos, equipment jostling, and the need for quick accessibility. From meticulous design to the final product, every step showcases Titan AV's dedication to precision and quality. 

Your gear deserves nothing less than the best!

by Titan AV on February 23, 2023

For this demonstration we used EVA 1000×1000×30mm, Black & Blue Shadow Foam. It has a 5mm black layer on top of a 25mm blue layer. We have a variety of thicknesses for our dark grey EVA foams, from 3mm to 50mm thick. EVA is a great foam for custom case organization, whether with a trim router or CNC machine cutting.

by Hans Bos on February 15, 2023

I am intrigued by the demo on EVA foam, How thick is it? is it available in different thicknesses?
I am interested to use it in a camera case, regards HB


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