How to Custom Cut EPE Foam

by Shannon on November 03, 2020

Today we’ll show you How To Custom Cut EPE Foam In 5 Easy (DIY) Steps!

To begin you’ll need:

  1. EPE Foam (also known as Peel Foam or Kaizen Foam)
  2. Felt tip pen
  3. Stanley knife or similar blade, &
  4. The equipment you want to fit.

For this demonstration we’re using the Titan AV EPE shadow foam insert designed to perfectly fit our Titan AV 2RU rack drawers.


Step 1: Layout

Play around with the layout to see what works best for your gear. Remember to leave enough space between objects + it’s important to check that the foam is deeper than your object to ensure it’s fully protected, if it isn’t you may need to rotate your object to fit.

How to Custom Cut Foam: Layout Your Equipment

Once you’re happy with your layout...

Step 2: Trace

Grab a sharpie or felt tip pen & trace around your gear.

Step 2: Trace Your Equipment

Pro Tip: You can pick up an extra long tip marker for precision tracing.

Empire Long Tip Marker

Step 3: Cut

First, measure the depth of your blade against your gear to ensure the perfect depth of cut.Step 3: Cut Your Foam

Hold your blade at a 90 degree angle for a clean cut. Carefully cut within your lines - remember, it’s easier to cut more foam out than add back in.

Step 3: Cut Your EPE Foam

Step 4: Peel

Keep your finger under the foam to peel out what you don’t need.

Step 4: Remove / Peel The Foam

Step 5: Test the fit

If anything doesn’t quite fit - repeat steps 3-5 as required. 

Step 5: Test the fit of your foam insert

If you have a deeper piece of equipment you may need to cut another layer of EPE foam for complete protection. If this is the case, simply lay your top layer of cut foam onto your second foam sheet and trace around the deepest part of your gear. Then cut & peel as required, this may take a few goes to get the exact fit you're after. 

Cut finger grips for your custom foam insert

Additionally, if you’d like to create finger grips for easier access, simply place a 20cent piece where you’d like to grab your gear & trace around it.

Custom Cut EPE Foam Insert for 2RU Drawer

And there you have it, custom cut foam in 5 simple steps with Titan AV EPE foam.

You can pickup one of our CNC pre-cut EPE foam inserts to suit Titan AV 2RU 3RU & 4RU 19" rack drawers - and create your own custom foam protection that ensures your sensitive equipment will get from A to B without a problem. With anti-vibration and anti-shock features Titan AV EPE foam is the perfect packing and storage solution.



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