Peli Air 1525 Replacement Foam Set

When the factory foam wears out or your equipment changes, the official Peli Air 1525 Replacement Foam Set restores your carry-on case to full protective performance. Manufactured to the exact interior dimensions of the Peli Air 1525, this black pick-n-pluck foam set lets you create a perfectly fitted, custom interior — without tools, without guesswork, and without buying a new case.

Pick-n-Pluck Foam: Simple, Precise, No Tools Required

The set consists of multiple black foam layers. The main layer is pre-scored into small, uniform cubes — each one can be removed by hand with a simple peel-and-pull motion. Place your equipment on the foam, mark the outline with tape or chalk, and remove the cubes within the marked area. The result is a snug, form-fitting cavity that holds your gear securely in position during transport.

One critical rule: always leave at least one centimetre of foam between your items and the case walls. That surrounding border of foam is what absorbs impacts, vibrations, and the occasional hard drop in transit. Cutting too close to the edges significantly reduces the protection the case was engineered to provide.

The solid base layer sits beneath the customisable pick-n-pluck section, providing a uniform cushioning foundation across the entire case floor. Together, the layers create a protective system that distributes force evenly and keeps sensitive equipment isolated from external shock.

When to Replace Your Foam

Carry-on cases lead demanding lives. Security screening conveyors, overhead lockers, tight transfers through busy airports — after enough journeys, even quality foam begins to compress permanently, tear, or lose its resilience. A replacement foam set gives your trusted Peli Air 1525 shell a completely fresh interior at a fraction of the cost of a new case.

A fresh foam set is equally valuable when your equipment changes. Each custom layout is configured around a specific kit; when that kit evolves — a new camera body, updated lenses, different audio hardware — a replacement set lets you start the customisation process from scratch on a clean surface, without any trace of the previous configuration.

Who Relies on the Peli Air 1525

The Peli Air 1525 is a carry-on-sized hard case trusted by photographers, videographers, drone operators, audio engineers, and other professionals who cannot afford to check sensitive equipment into the hold. Designed to meet most airline carry-on size requirements, it stays in the cabin — which means it must be packed efficiently and protectively every single time.

A well-configured pick-n-pluck interior is one of the most effective ways to achieve that standard consistently. Each item has its own dedicated cutout, cannot shift during flight, and is cushioned on all sides. For professionals whose work depends on arriving with working equipment, that reliability is not optional.

Fit and Compatibility

This foam set is manufactured specifically for the Peli Air 1525 case and matches its interior dimensions exactly. It will not fit other Peli Air series cases. Check the model designation printed inside your case lid before ordering to confirm you have the correct model.

Material and Care

The foam is made from open-cell polyurethane — chosen for its combination of cushioning performance, flexibility, and long-term durability. It compresses and recovers reliably across a high number of packing and unpacking cycles. Keep the foam dry and avoid prolonged exposure to direct sunlight, which gradually degrades polyurethane cell structure over time.