Custom Foam Fabrication from Royal Case Company


Custom Foam Fabrication from Royal Case Company

At Royal Case, we have spent the last 25 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. We can design custom foam inserts to display and protect the contents of your case.

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


Did you know? RCC makes a complete line of EVA cases.

Complete Services from A to Z Gets the Job Done Right.

CAD Design

A quality product begins with quality design. Our CAD designers will work with your products to ensure a custom fit every time.

Finishing Touches

Our finishing options help 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.

Warehousing Options

Royal Case Company has 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 that sets you apart from your competition.

Get a Free Custom Foam Sample For Your Next Project.

Just make your request and we’ll get it in the mail within 24 hours.

We’d like to quote your next custom foam project today to show you how eager we are to be your preferred vendor. We’ll call you, if you’ll use this contact form or you can call us at the number above.

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