Custom Hard Case Insert Builder

Name: Custom Hard Case Insert Tray
Brand: DC Additive Pros
Availability: MadeToOrder

A hard case insert tray is a rigid 3D printed tray with a pocket for each tool that drops into your case in place of pick foam. DC Additive Pros makes them to order for field techs, test and measurement kits, labs and makers. Pick a case compatible with the Pelican 1120, 1150, 1170, 1200, 1300 or 1400, or enter your own case size, add your tools, and see the layout and price before you pay. Trays start at $59.95 (a 1400 tray for a multimeter, two probes, a clamp meter and a bit case is $78.95), free US shipping is included, and every tray is made in the USA in Rockville, Maryland.

Rigid PETG wipes clean, does not shed foam dust or soak up oil, and keeps every tool in the same place so a missing one is easy to spot.

Organizer only. We make no water, dust, drop, impact or static (ESD) rating claims for the insert. Pelican is a trademark of Pelican Products, Inc. DC Additive Pros is not affiliated with or endorsed by Pelican. Presets are sized from the inside dimensions the case maker publishes.

Build your case insert

Case

I measured the inside floor of my case (optional, most exact fit)

Floor length (mm)

Floor width (mm)

Inside floor length (mm)

Inside floor width (mm)

Bottom depth, floor to rim (mm)

Lid depth (mm)

Tool sizes in

Clearance around each tool

Pocket depth

Finger notches

Tray height

Height (mm, 12 to 60)

Foam under the tray (mm)

Lid foam

Color

Identical trays

Notes for our team (optional)

Top view preview. Light shapes are pockets, half circles are finger notches, the dashed line is the case inside size. Our team checks every layout before printing.

$0.00

Free US shipping included. Made in USA.

I confirm my case model (or measured size) and tool sizes are right, and I understand this tray is an organizer only, with no water, drop, impact or ESD rating.

Larger cases or your own tray file: upload it to the instant 3D printing quote for a price you can pay online. Drawers: use the toolbox drawer organizer.

How it works

Each pocket is your tool length and width (or diameter) plus the clearance you pick, with rounded corners and an optional finger notch.
The tray is sized a little under the published inside size of the case so it clears the case walls as they taper toward the floor, with 10 mm rounded corners. Measured a real case? Enter the floor size and we leave 1.5 mm per side.
The builder keeps a 6 mm rim and 4 mm walls between pockets, checks that every tool fits under the closed lid, and blocks checkout when something does not fit.
Trays up to 330 x 310 x 60 mm are priced instantly in one piece. Every order gets a layout check by our team before printing.

Hard case insert FAQ

What is a hard case insert tray?

It is a rigid 3D printed PETG tray with a pocket for each of your tools that drops into the bottom of a hard case in place of pick foam. Pockets are sized from the tool length, width and thickness you enter, plus a clearance of 1.0 to 2.5 mm per side, with optional finger notches. A tray for a case compatible with the Pelican 1400 holding a multimeter, two probes, a clamp meter and a bit case is $78.95 with free US shipping.

Which cases does the builder support?

Presets are compatible with the Pelican 1120, 1150, 1170, 1200, 1300 and 1400 Protector cases, sized from the inside dimensions the case maker publishes. You can also enter the inside floor size and depth of any other hard case. Trays are limited to 330 x 310 mm in one piece, so the 1450, 1500 and larger cases are not in this builder yet. DC Additive Pros is not affiliated with or endorsed by Pelican Products, Inc.

How much does a custom case insert cost?

The builder shows the exact price before checkout. Trays run from $59.95 to about $125.95 each depending on tray size and height, and the price includes free US shipping. Two identical trays are 5% off each and four or more are 10% off each.

How do I give you the size of my tools?

Measure each tool at its longest, widest and thickest points in mm or inches and enter it as a rectangle or a round. Set how many pockets you want for each tool. The builder packs the pockets into the tray, shows a top view, and blocks checkout if the tools do not fit or would stand too tall for the closed lid.

Can I keep the case foam?

Yes. You can keep the lid foam, and you can keep a layer of the original base foam under the tray to lift it toward the rim. Enter the foam thickness under the tray and the builder adjusts the tray height limit and the lid clearance check.

Does the insert make my case waterproof or drop proof?

No. The insert is an organizer only. We make no water, dust, drop, impact or static (ESD) rating claims for the insert, and it does not change any rating of the case itself. PETG softens above about 70 C, so do not leave the case in a hot vehicle with the tray loaded.

What is the tray made of, and where is it made?

Each tray is 3D printed in PETG, a tough, easy to wipe plastic, and made to order in the USA by DC Additive Pros in Rockville, Maryland. Every order gets a layout check by our team before printing.