What information is needed for a custom foam insert?

An existing case or a new shell?

First establish which shell will hold the insert. For an existing case, start with the make, model, usable interior dimensions and an open-lid photograph. If a new shell is needed, start with the complete equipment and accessory list rather than the main device alone.

• Record base and lid depth separately.
• Show corners, internal obstructions and any existing lid storage.
• Do not substitute exterior dimensions for usable interior dimensions.

Describe every item separately

List the cables, chargers, probes, batteries and spare parts that travel with the main device. Dimensions, quantities and a photograph of each item help define the layout. If several equipment versions will be used, identify the differences instead of assuming they share the same dimensions.

• State whether all items travel together or in separate sets.
• Mark displays, lenses, controls and connections that need consideration.
• Identify accessories that may be added later.

Plan removal as well as fit

Describe the layout in the order it will be used. Consider whether removing a frequently used item would require taking other items out first. State where the device can be gripped and whether gloves are used. Finger access, separators and clearances are assessed together with the equipment geometry.

Describe operating conditions for material selection

Do not select material by colour or appearance alone. State equipment weight, handling frequency, expected contact substances, cleaning method and storage conditions. If antistatic properties or a particular test standard are required, provide them as specifications. Properties of one foam or shell model should not be assumed to apply to every assembled solution.

Use the same checklist for drawing and sample review

Match each cavity in the proposed layout to an item in your equipment list. Sample review checks fit, access, closure and accommodation of all accessories. Update the drawing whenever dimensions or equipment versions change. This checklist is not a certified resistance test; any required testing has a separate scope.