After all necessary measurements are acquired, a model is developed in Inventor.
Toolpaths for CNC table are created and the .cnc file is posted to the specific custom foam folder.
This is the first of two pages of the setup sheet given to the CNC table operator.
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This is the second of two pages for the CNC table.
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Here is a screenshot of an Inventor 3D PDF.
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This Inventor drawing specifies the depth dimensions for the main body of foam; this will be used once the foam is cut to ensure the merchandise will fit correctly.
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This Inventor drawing specifies the dimensions for the foam tray, which will not be glued and can later be removed by the customer.
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This Inventor drawing specifies the depth dimensions for the foam tray.
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This Inventor drawing defines the proper order for gluing the foam to the ordered case. These instructions can become quite complex with much larger orders.
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This Inventor drawing specifies the orientation of labels, if necessary.
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Here is the final product.
Thank you, Coroflot, for redoing your page and making my pictures upside down.
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Custom Foam

Custom foam for Pelican cases.
(150+ including guns and sensitive equipment serving both personal and professional customers alike)

John Gates
Industrial Designer Lawrence, KS