Power Tool Case Inlays

About Power Tool Case Inlays

Power tool case inlays are precision-cut foam inserts designed to fit inside modular storage systems, providing secure, organised storage for professional power tools and accessories. These foam inlays feature pre-cut compartments or customisable grid patterns that cradle tools snugly, preventing movement during transport and protecting expensive equipment from damage. The foam construction absorbs shock and vibration whilst keeping tools readily accessible, making them essential for tradespeople who need to transport their kit between job sites safely and efficiently.

Most power tool case inlays are designed to fit specific storage systems such as the Bosch L-Boxx, DeWalt TSTAK, Milwaukee PACKOUT, Makita MakPac, and Festool Systainer ranges. These modular systems allow multiple cases to stack and lock together, creating a portable workshop that can be transported as a single unit. The inlays themselves come in two main varieties: tool-specific inlays with pre-cut shapes designed for particular models, and universal foam inserts with removable cube sections that can be customised to accommodate any tool configuration.

Tooled-Up.com stocks a comprehensive range of power tool case inlays predominantly from Bosch Professional, covering multiple L-Boxx sizes to suit different tools and storage requirements. These foam inserts transform basic storage cases into professional-grade transport solutions, extending tool life by preventing knocks and scratches whilst dramatically improving site efficiency by keeping everything organised and easy to locate.

Jargon Buster

• L-Boxx System: Bosch's modular stackable case system with standardised dimensions (sizes 102, 136, 238, 374) that allows multiple cases to connect and be carried together. Numbered sizes refer to internal height in millimetres.
• Pre-Cut Inlay: A foam insert with pre-formed compartments specifically shaped to fit particular tool models perfectly, providing maximum protection without requiring customisation.
• Grid Foam Insert: A universal foam inlay featuring a matrix of removable cubes or squares that can be plucked out to create custom-shaped compartments for any tool configuration.
• Modular Storage System: Stackable, interlocking tool storage cases that share common dimensions and connection points, allowing tradespeople to build customised transport solutions from compatible units.
• Shadow Board Layout: An organisational method where tools are stored in precisely shaped compartments, making it immediately obvious if any item is missing—particularly useful for site work and tool accountability.
• High-Density Foam: The durable foam material used in quality inlays that maintains its shape over time, resists compression, and provides excellent shock absorption for tool protection.

Who Uses Power Tool Case Inlays?

• Electricians and Sparkies: Keeping drills, impact drivers, multi-tools and testing equipment organised during domestic and commercial installations
• Joiners and Chippies: Protecting routers, jigsaws, planers and circular saws whilst moving between workshop and site
• Plumbers: Securing pipe cutters, crimping tools and specialist power tools during van-to-site transport
• General Builders: Maintaining multiple cordless tools and accessories in organised, stackable systems on busy construction sites
• Maintenance Engineers: Transporting diagnostic equipment and repair tools between facilities safely and efficiently
• Mobile Service Technicians: Keeping specialised tools protected and accessible when travelling between customer locations
• Shopfitters and Installers: Protecting finishing tools and precision equipment during commercial fit-out projects
• Serious DIY Enthusiasts: Maintaining a professional standard of tool organisation and protection in home workshops
• Tool Hire Companies: Presenting equipment professionally whilst ensuring tools return complete and undamaged

How to Choose the Right Power Tool Case Inlays

Check System Compatibility: Ensure the inlay matches your existing storage system. Bosch L-Boxx inlays only fit L-Boxx cases, whilst DeWalt TSTAK and Milwaukee PACKOUT systems require their own specific inserts. Verify the size designation—L-Boxx systems come in sizes 102, 136, 238 and 374, referring to internal case height.

Tool-Specific vs Universal: Decide whether you need a pre-cut inlay designed for specific tool models or a customisable grid foam insert. Tool-specific inlays from Tooled-Up provide perfect-fit protection but only accommodate designated equipment, whilst universal grid foam offers flexibility to accommodate any tools you own or acquire in future.

Assess Your Tool Collection: Count the tools you need to store and consider their dimensions. Larger tools like circular saws or angle grinders require deeper cases with size 3 or 4 inlays, whilst compact drivers and multi-tools fit comfortably in size 2 cases with appropriate inserts.

Consider Accessory Storage: Factor in space for batteries, chargers, drill bits, saw blades and other accessories. Some inlays include dedicated compartments for consumables, whilst others focus solely on the main tool body.

Think About Workflow: Consider how frequently you access certain tools. Items used together should be stored in the same case with coordinated inlay layouts, whilst less-used equipment can occupy separate stackable units.

Foam Quality Matters: Professional-grade foam inserts use high-density material that won't compress or crumble with repeated use. Cheaper alternatives may save money initially but deteriorate quickly, failing to protect expensive tools properly.

Popular Accessories

• Additional L-Boxx Cases: Extra storage cases in various sizes to expand your modular system as your tool collection grows
• L-Boxx Trolleys and Caddies: Wheeled transport solutions that accept multiple stacked cases for easier site mobility
• Lid Organisers: Transparent compartmentalised lids for storing small consumables, fixings and accessories
• Divider Sets: Adjustable partitions for organising loose items in cases without dedicated foam inlays
• Case Locks and Latches: Replacement or upgrade locking mechanisms for enhanced security during transport
• Tool Wrap and Barrier Cloth: Additional protective layers for particularly delicate or valuable equipment
• Silica Gel Sachets: Moisture control for tools stored long-term or in damp site conditions
• Foam Cutting Tools: Specialised knives and templates for customising universal grid foam inserts precisely

Frequently Asked Questions

Can I cut custom shapes into universal grid foam inserts?

Yes, universal grid foam inserts feature small removable cubes that can be plucked out by hand or carefully cut with a sharp knife to create custom tool shapes. The grid pattern provides guidelines for creating neat, professional-looking compartments. For best results, trace your tool outline onto the foam before removing sections, and test-fit regularly during the customisation process.

Will inlays designed for one L-Boxx size fit other sizes?

No, L-Boxx inlays are size-specific. A size 2 inlay (for 136mm internal height cases) won't fit size 3 or size 4 cases. Always verify the size designation before purchasing. The numbering system relates to case depth, so matching the correct inlay to your case size is essential for proper fit and tool protection.

Do foam inlays protect tools during van transport?

Yes, high-quality foam inlays significantly reduce damage during transport by preventing tools from rattling against case walls or each other. The foam absorbs shock and vibration, protecting delicate components, precision adjustments and painted finishes. This is particularly valuable for expensive 240v professional tools and cordless equipment with electronic components sensitive to impact damage.

Can I wash foam inlays if they get dirty?

Foam inlays can be spot-cleaned with a damp cloth and mild detergent, but shouldn't be fully submerged or machine washed as this may cause the foam to break down or lose its shape. For site-dusty foam, use a vacuum cleaner or compressed air to remove debris. Allow any damp foam to dry completely before returning tools to prevent moisture damage.

Are there inlays available for cordless tool batteries and chargers?

Yes, many tool-specific inlays include dedicated compartments for batteries and chargers alongside the main tool. Universal grid foam can also be customised to accommodate battery packs safely. Storing batteries in foam inlays protects terminals from short-circuit risks and prevents the physical damage that reduces battery life, making it a worthwhile investment for expensive lithium-ion battery systems.