When choosing foam for a protective case, it's important to understand that not all foam materials offer the same level of protection, durability, practicality or presentation. Here we discuss the differences between PU/open cell and PE/closed cell foam inserts.
Foam Guides
Designed to create custom foam inserts without specialist cutting equipment, cubed foam allows users to quickly tailor a protective case to the exact shape of their items. Whether you're storing cameras, drones, measuring equipment, test instruments, power tools or sensitive electronics, cubed foam provides an easy way to improve protection and organisation.
Whether you're protecting expensive tools or delicate electronics, or presenting a premium product, the right foam insert can make all the difference.
Cases FAQ
How do I choose the right protective case?
The best case depends on the size, weight and value of the equipment you need to protect. Consider the internal dimensions, level of protection required, transport conditions and whether you need a custom foam insert.
What size case do I need?
Measure the length, width and height of your equipment, including any accessories. You should allow enough space around the contents ensure the contents remain protected during transport.
Are your protective cases waterproof?
ROC Cases are splashproof. If you are looking for advanced water protection, our Hurricane cases have an IP67 rating and feature waterproof seals designed to help protect contents from water and dust. Always check the specifications of the individual case for its level of protection.
What are hard cases used for?
Hard cases are designed to protect valuable equipment during storage and transport. They are commonly used for tools, electronics, cameras, measuring equipment, drones, medical devices and test instruments.
Do I need foam inside my case?
Foam helps prevent equipment from moving during transport and provides additional protection against knocks, impacts and vibration. For valuable or fragile equipment, foam inserts are strongly recommended.
Can I buy a case with custom foam already fitted?
Yes, many cases can be supplied with bespoke foam inserts tailored to the equipment being stored. For more information about custom cases, click here
Do your cases lock?
Yes - most of our cases have catches which feature padlock loops, ideal for keeping valuables safe. Our B026 case features combinations locks.
What is a ROC Case?
ROC Cases is a brand of lightweight aluminium frame cases designed for the safe storage, transport, and protection of various equipment. Established in 2003, ROC Cases has extensive experience in offering durable and versatile cases to meet a wide range of needs.
what is a ROC PRO case?
ROC PRO is a range of heavy duty flight cases which boast thicker panels than other cases on the market. Featuring standard or detachable lids, these cases come in a range of sizes with various foam options available.
what is a Hurricane case?
The Hurricane range of high-quality protective case is designed to provide superior protection for your equipment in all weather conditions and from impact damage. Established in 2003, Hurricane Cases are fully tested to ensure they offer exceptional durability, with protection comparable to that of Peli cases.
These cases are ideal for storing and protecting a wide range of equipment, including DSLR cameras and lenses, airsoft gear, electronics, and scientific instruments.
Key Features of Hurricane Cases:
- IP67 Rated: Watertight, airtight, and dustproof for ultimate protection in harsh environments.
- IK08 Rated: Shockproof and crushproof to withstand impacts and drops.
- Pressure Equalisation Valve: Helps adjust internal air pressure to keep your items secure.
- Chemical Resistant & Anti-Corrosive: Built to resist damage from chemicals and corrosion.
- Water Immersion Resistance: Withstands immersion in water up to 1m for up to 30 minutes.
- Temperature Range: Operates from -20°C to 60°C (with short-term use from -40°C to 80°C).
- High-Density Foam: Includes cubed foam layers and an egg foam lid insert for extra protection.
- Additional Features: Secure padlock loops, watertight rubber gasket 'O' ring, foldable carry handle, strong steel pin hinge design, and heavy-duty construction.
Difference Between Hurricane Cases and ROC Cases:
While both Hurricane and ROC cases provide excellent options, the key differences between them lie in their design and intended use:
- Purpose and Protection:
- Design Features:
- Weight and Durability:
Ultimately, Hurricane Cases are better suited for harsh conditions and extreme protection, while ROC Cases offer reliable, lightweight storage for less demanding environments.
What are IP and IK ratings?
IP (Ingress Protection) and IK (Impact Protection) ratings are industry standards used to define the level of protection provided by enclosures or cases against various environmental factors, such as dirt, moisture, and physical impacts.
These ratings are defined in international standards:
- IP Ratings are based on EN 60529 (British BS EN 60529:1992, European IEC 60509:1989).
- IK Ratings are based on EN 62262 (British BS EN 62262:2002, European IEC 62262 Ed. 1.0 B:2002).
Understanding IP Ratings
The IP rating consists of two digits:
- The first digit indicates protection against solid objects (e.g., dust, tools, etc.).
- The second digit indicates protection against moisture (e.g., rain, splashes, immersion).
Here’s a breakdown of each number:
First Digit - Protection Against Solid Objects:
- 0: No protection.
- 1: Protection against objects 50mm or larger (e.g., hands).
- 2: Protection against objects 12mm or larger (e.g., fingers).
- 3: Protection against objects 2.5mm or larger (e.g., tools or wires).
- 4: Protection against objects 1mm or larger (e.g., small wires).
- 5: Dust protected (dust does not interfere with operation).
- 6: Dust tight (no ingress of dust).
Second Digit - Protection Against Moisture:
- 0: No protection.
- 1: Protection against dripping water (vertical drops).
- 2: Protection against dripping water when tilted up to 15º.
- 3: Protection against spraying water (up to 60º angle).
- 4: Protection against splashing water (from any direction).
- 5: Protection against water jets (from a nozzle).
- 6: Protection against heavy seas (powerful water jets).
- 7: Protection against temporary immersion (defined pressure and time).
- 8: Protection against continuous immersion (as specified by the manufacturer).
Understanding IK Ratings
The IK rating measures the impact protection of an enclosure. It is indicated by a two-digit number:
- IK00: No protection.
- IK01 to IK10: Protection against increasing levels of impact energy, measured in joules (J).
For example:
- IK01: Protected against 0.14 joules (equivalent to a 0.25 kg mass dropped from 56mm).
- IK10: Protected against 20 joules (equivalent to a 5 kg mass dropped from 400mm).
This rating helps determine how well a case or enclosure can withstand physical impacts, such as knocks or drops.
Summary
- IP Ratings specify how well a case resists dirt and moisture.
- IK Ratings specify how resistant a case is to physical impacts.
Both ratings help you assess the durability of cases in various environments.
How do you reset a Cases and Enclosures combination padlock?
Follow these simple steps to reset your combination padlock:
- Unlock the Padlock: Set the combination code to “000” to unlock the padlock.
- Open the Padlock: When the lock is open, rotate the hook 90 degrees anti-clockwise to align with the slot.
- Set the New Combination: Hold the hook down and enter your desired combination.
- Secure the Lock: Once your new combination is set, twist the hook back into place.
- Lock the Padlock: Enter any random combination to lock it again.
For a visual guide, you can watch our user-friendly video to learn how to set and reset your combination lock in just 1 minute. Click here to view the video.
Foam Inserts FAQ
What is the difference between PU foam and PE foam?
PU (Polyurethane) foam is a softer, open-cell foam that provides excellent cushioning and is commonly used for pick and pluck foam, egg crate foam and general protective packaging. PE (Polyethylene) foam is a denser, closed-cell foam that offers greater durability, water resistance and structural support.
Is PE foam better than PU foam?
Neither material is inherently better. PU foam is ideal for lightweight equipment, DIY customisation and general cushioning, while PE foam is better suited to applications requiring long-term durability, precise fitment and professional presentation.
Is cubed/pick and pluck foam made from PU or PE foam?
Pick and pluck foam is typically manufactured from polyurethane (PU) foam. Its softer structure allows the pre-scored cubes to be easily removed by hand, creating custom-shaped compartments without specialist tools.
What is closed-cell foam?
Closed-cell foam contains tightly packed cells that are sealed from one another. This structure helps prevent water absorption and gives the foam greater rigidity and durability. PE foam is a common example of a closed-cell foam.
What is open-cell foam?
Open-cell foam contains interconnected air pockets, making it softer and more compressible. PU foam is an open-cell foam, which helps provide excellent cushioning and impact absorption.
What foam is best for flight cases?
The best foam depends on the application. For heavy or valuable equipment, PE foam is often preferred due to its durability and ability to securely hold items in place. PU foam is commonly used as lid foam or for lighter-duty cushioning.
What foam is used for CNC-machined inserts?
PE foam is typically used for CNC-machined inserts because its dense, closed-cell structure allows clean, accurate machining and provides long-lasting protection for tools, instruments and sensitive equipment.
Is PE foam waterproof?
PE foam is highly water resistant due to its closed-cell structure. This makes it suitable for applications where equipment may be exposed to moisture, humidity or challenging environments.
Can I customise foam inserts myself?
Yes. Pick and pluck foam allows you to create custom compartments by removing pre-scored cubes by hand, making it an excellent DIY solution for equipment protection. Plain PU foam can be cut easily with a craft knife.
How do I choose the right foam for my case?
If you need a simple, cost-effective and easy-to-customise solution, PU foam is often the best option. If you require a precision-cut insert for valuable equipment or regular transportation, PE foam is usually the better choice.
Can you manufacture bespoke foam inserts to match my equipment?
Yes. We can produce bespoke CNC-machined foam inserts designed around your tools, instruments or equipment. Simply provide dimensions, drawings or CAD files, and we can create a custom foam solution tailored to your requirements (minimum order quantity of 10 pieces applies).
Which foam is best for cameras and electronics?
For general storage, pick and pluck foam offers a simple customisable solution. For professional transport and maximum protection, a custom PE foam insert may be more suitable.
Which foam is best for lightweight or delicate items?
PU open cell foam provides excellent cushioning and is often used for delicate products that require protection from knocks and vibration. We sell PU foam as plain or cubed foam inserts, and egg foam sheets.
Do I need pick and pluck foam or a custom insert?
Pick and pluck foam is ideal for DIY customisation and smaller budgets, while custom CNC foam inserts offer a more precise, professional and durable solution.
How easy is pick and pluck foam to customise?
Pick and pluck foam can usually be customised by hand without specialist tools by removing pre-cut cubes to match the shape of your equipment. See our guide for more information.
Can pick and pluck foam be reused?
Yes, although repeated changes may reduce the foam's appearance and structural integrity. If the layout is likely to change frequently, replacement foam may eventually be required.
Is pick and pluck foam suitable for professional use?
It can be, but organisations requiring a more professional appearance often choose CNC-machined PE foam inserts instead.
What is egg crate foam used for?
Egg crate foam is commonly used in case lids to help hold equipment securely in place when the case is closed.
Can egg crate foam be used on its own?
It is usually paired with another foam insert or base layer for complete protection.
Why is PE foam used for CNC machining?
Its dense structure allows precise, clean cuts and produces a professional-looking insert with excellent durability.
Does PE foam absorb water?
PE foam's closed-cell structure makes it highly water resistant, making it suitable for demanding environments.
How long does PE foam last?
PE foam is extremely durable and can retain its shape and protective properties for many years with normal use.
Can I replace the foam in my existing case?
Yes, foam inserts are not glued in place, they can be easily removed. Our foam inserts are designed to fit in our range of cases - if you are looking for a foam insert for a different brand, make sure to check dimensions before ordering.
Can you create foam inserts from a CAD drawing?
Yes, we can work from CAD files such as DXF, DWG and other common formats.
Can you create a foam insert from a photo?
In many cases, yes. Additional dimensions may be required to ensure an accurate fit. Many customers send us a sample of what is to be placed in the case, so we can create the ideal design. Please contact us for more information.
What information do you need to quote for a custom foam insert?
Typically we require the case dimensions, product dimensions, quantities and any drawings or images available.
Is there a minimum order quantity for CNC foam inserts?
yes, there is a minimum order quantity of 10 pieces.