TacRugged engineers precision-cut foam and full case customizations for Pelican-Hardigg™ platforms, purpose-built for defense, aerospace, and field-deployed equipment.
TacRugged waterjet-cuts custom foam inserts from a wide range of material types, matched to your equipment’s weight, sensitivity, and environmental exposure. Every insert is designed around a specific load path, not adapted from a generic template. Whether you’re protecting calibrated instruments or crew-served weapons, the foam spec starts with your application.
Polyethylene Foam
Strong, non-abrasive, and water-resistant with excellent vibration dampening. Available in various densities. The workhorse material for most defense and field applications.
Polyurethane Foam
Softer open-cell foam, best suited for lighter-weight sensitive equipment such as laptops, cameras, and precision instruments where surface contact matters.
Cross-Link Foam
Non-porous, non-particulate closed-cell foam commonly used in clean room environments. Reduces foreign object debris, critical for optics and sensitive assemblies.
Anti-Static Polyethylene
Closed-cell foam with anti-static properties that slowly dissipate electrostatic charges. Specified for circuit boards, avionics components, and ESD-sensitive electronics.
Anti-Static Polyurethane
Open-cell, lightweight foam that inhibits static buildup. Used where both cushioning and ESD protection are required, such as test sets and measurement instruments.
We start by understanding the equipment, environments, and mission.
We spec the right case and create a custom foam interior.
We create a ready-to-deploy solution. No guesswork. No compromises.
Understanding Foam Terminology
Manufacturer:
The company that produces the raw foam material (e.g., Sealed Air, SEKISUI Voltek, Zotefoams).
Brand:
The trademarked product name (e.g., Ethafoam, Volara, Plastazote).
Material Type:
The general category of foam (e.g., polyethylene (PE), polyurethane (PU)).
Process / Structure:
How the foam is made (e.g., cross-linked, non-crosslinked, fine-cell).
Primary Foam Categories
Non-Crosslinked Polyethylene (PE) Foam
Examples: Ethafoam, PolyPlank
Best for: Rugged transport, heavy equipment, cost-effective protection
Pros: Durable, water-resistant, cost-effective
Cons: Coarser appearance, less refined finish
Fine-Cell Polyethylene Foam
Example: Ethafoam Synergy
Best for: Applications needing both protection and improved presentation
Pros: Cleaner look, lower abrasion surface
Cons: Slightly higher cost than standard PE
Cross-Linked Polyethylene (XLPE) Foam
Examples: Volara, Plastazote, Minicel
Best for: High-end presentation, delicate components, medical or aerospace use
Pros: Smooth surface, fine cell structure, premium appearance
Cons: Higher cost, sometimes unnecessary for rugged applications
Cut and Weld Solutions
When equipment won't fit a standard case, TacRugged engineers a solution from the ground up. The cut-and-weld process builds custom dimensions and oversize containers from Pelican-Hardigg™ host cases, rejoined with a polymer rod weld that produces a seam stronger than the adjacent wall panels and is guaranteed watertight. Oversized payloads, consolidated assemblies, systems that need a case built around them: we scope it, spec it, and deliver it ready to deploy.
Deck and Cradle Suspension
Some payloads are too heavy or too fragile for foam alone. TacRugged engineers custom deck and cradle suspension systems when structural isolation is part of the mission requirement, with punch press, metal CNC, and certified welding built to the standards demanded by aerospace, defense, and medical programs. You get a mounting solution designed around your specific hardware, not a workaround.
Let us customize foam inserts to your mission.
Personalize the outside of your case to match your company’s branding. Add your logo with our hot stamp imprint process, which is scratch resistant; or add a custom logo decal or engraved name plate.
Engraved Name Plate
Custom Logo Decal
Vibrant Hot Stamp Imprint
Tell us what you are protecting and how it is handled and we will build the right Pelican-Hardigg™ solution.
A Pelican™ case is a rugged, molded protective case known for being waterproof, crushproof, and dustproof, commonly used to protect sensitive equipment in military, industrial, photography, and scientific applications.
Professionals typically use CNC routing, waterjet cutting, laser cutting, or die cutting to precisely cut foam inserts that match the shape of the stored equipment.
Pelican-Hardigg™ cases are engineered to be watertight and meet MILSTD and IP ratings depending on the model and the requirement.
They are created using CAD design followed by CNC routing, waterjet cutting, or laser cutting to produce precise cavities for equipment.
No, Pelican™ cases are not rated as fireproof. They are heat-resistant but not designed to withstand fire.
Most Pelican™ cases are made from injection-molded polypropylene or a polypropylene copolymer. Pelican-Hardigg™ cases are made from rotationally molded polyethylene.
Work with us. TacRugged specializes in custom foam.
Berry compliance means the product is manufactured in the USA with domestically sourced materials, as required under the Berry Amendment for certain DoD purchases.
Through authorized Pelican™ distributors, industrial supply companies, defense suppliers, or directly from Pelican’s official sales channels.
They’re used for military, aerospace, industrial, and scientific equipment transport - especially when impact, vibration, and environmental protection are critical.
Yes. They include an automatic pressure equalization valve, letting them remain airtight while preventing vacuum lock.
Yes. Hard cases like Pelican™ are TSA acceptable as long as they are lockable with non-TSA locks and follow airline firearm transport rules.
Most Pelican™ Protector and Pelican-Hardigg™ cases include Pelican’s lifetime guarantee (with some exceptions such as electronics and soft goods).
Yes. They offer durability, environmental sealing, impact resistance, and consistent compliance with many military standards.
Common foams include polyurethane (PU) for soft cushioning and polyethylene (PE) for firmer, structural support.
Yes. CNC-cut custom foam is available from many case-and-foam fabricators.
Many Pelican™ cases do float when loaded below their buoyancy limit. Each model has a published buoyancy rating.
From us. TacRugged specializes in custom foam.
Pelican™ cases are injection-molded; Pelican-Hardigg™ cases are rotationally molded. Pelican-Hardigg™ cases are thicker, heavier, and better suited for heavy-duty military and industrial shipping.
Yes. Many models do have NSNs for military procurement.
You found us.
Yes. Pelican-Hardigg™ manufactures shock-mounted rackmount transit cases for electronics, servers, and communication systems.
Common materials include:
• Polyethylene (PE) foam
• Polyurethane (PU) foam
• Crosslinked polyethylene (XLPE)
• Ethafoam
• Zotefoams (Plastazote)
ISP stands for InterStacking Pattern. These cases have a patented pattern that locks cases together for stable palletization and shipping.
It’s a fabrication technique where parts of multiple rotomolded cases are cut, reshaped, and welded together to produce custom-sized cases.
It’s a shock-mounting system used in Pelican-Hardigg™ cases, where equipment is suspended on an internal deck supported by elastomeric shocks, isolating gear from vibration and impact.
