What size foam do I need for my project?

Choosing the right size foam for your toolbox or storage project can make all the difference. Whether you are organising a small set of tools or fitting out a full drawer system, getting the sizing right helps you save time, reduce waste and get a cleaner finish.

At Shadow Foam, we have developed our range to make that choice as simple as possible, and our latest addition is designed to solve a very common problem.

Introducing our new 1200x600 mm foam sheets

We have added a new large sheet size of 1200 x 600 mm to our range.

Why this size? Because many toolbox drawers and storage systems are built around similar dimensions. Until now, customers often had to move away from standard sheets into custom sizes, which can be more expensive.

This new size gives you:

• A better fit for larger drawers and tool chests
• Less cutting and less waste
• A more cost effective alternative to custom foam

It is a simple addition, but one that makes a big difference for anyone working with larger storage setups.

Our full foam size range

We now offer a complete range of sizes to suit everything from small projects to full workshop setups:

• 400 x 320 mm → ideal for small projects or entry level use
• 600 x 420 mm → great value packs for general organisation
• 1000 x 500 mm → a versatile medium size for tool drawers sold in single sheets
• 1200 x 600 mm → our new large format for bigger storage systems

This range means most users can now find a suitable size straight off the shelf without needing to go custom. 

What if I have a specific toolbox or case?

If you are working with a specific toolbox or flight case, you might not need to measure or cut at all.

We offer a wide range of ready made inserts designed to fit popular toolboxes and cases. These are perfect if you want a faster solution with a precise fit straight out of the box.

How to choose the right foam depth

Size is only part of the decision. Choosing the correct foam depth is just as important to make sure your tools are properly protected and easy to access.

If you are unsure what depth you need, we have put together a detailed guide here:
https://shadowfoam.com/blogs/article/a-guide-to-shadowfoaming

This will walk you through how to match foam thickness to your tools and your storage setup.

More colour choice than anyone else

Organisation is not just about function, it is also about visibility and style.

Our foam is available in 9 vibrant colours, giving you more choice than any other supplier. Whether you want high contrast for quick tool identification or a clean branded look, there is an option to suit your setup.

When you need something more custom

While our standard sizes cover most needs, we know that not every project is standard.

If you need something specific, we offer a custom foam manufacturing service where we can produce foam in any size up to 2000 x 1000 mm. This is ideal for unique toolboxes, large scale storage or specialist equipment.

Finding the right fit

For most people, choosing the right foam size comes down to three simple steps:

1. Measure your drawer or case
2. Match it to the closest standard size
3. Choose the right depth for your tools

With the addition of our new 1200 x 600 mm sheets, it is now easier than ever to find a size that works without compromise.

If you are upgrading your toolbox or starting a new organisation project, there has never been a better time to get the perfect fit.