Peli Air 1535 Replacement Foam Set

Give Your Peli Air 1535 a Custom Interior — Built Around Your Gear

Your equipment is unique. Your carry-on protection should be too. The Peli Air 1535 Replacement Foam Set is the official factory foam insert designed specifically for the Peli Air 1535 carry-on case — restoring, upgrading, or completely reimagining the interior to fit exactly what you carry.

The Pick N Pluck System: Precision Without Tools

The foam set uses Peli's signature Pick N Pluck system. The black polyurethane foam comes in multiple layers, each pre-scored into a grid of small cubes. To create a custom cavity, simply lay your gear on the foam surface, trace the outline with chalk or masking tape, then pull out the cubes one by one to form a perfect snug recess. No cutting, no glue, no specialist tools required.

The result is a foam interior that holds every item securely in place, preventing movement and absorbing shock during transport. Each item sits protected on all six sides, cushioned against impact and vibration whether in the overhead bin, in a camera bag, or in transit on bumpy terrain.

Who Is This For?

• Photographers and videographers who travel with fragile camera bodies, lenses, and accessories and need a perfectly fitted case interior that protects every element individually.
• Field engineers and technicians transporting sensitive instruments, meters, or calibration equipment that must arrive intact and ready to use.
• Collectors and enthusiasts carrying watches, knives, pens, coins, or other valuables who want display-quality protection without a custom pelican case price tag.
• Medical and laboratory professionals carrying sample kits, diagnostic devices, or fragile vials where zero movement is non-negotiable.
• Frequent flyers whose original foam has worn out over years of use and who want to restore the case to factory-fresh protective performance.

How to Customise Your Foam

1. Remove the foam layers from the case and lay them on a flat surface.
2. Place your equipment on top of the foam in the desired arrangement.
3. Mark each item's footprint with masking tape or chalk.
4. Pluck out the scored cubes within each marked area — the pre-cut grid makes removal clean and consistent.
5. Test the fit. Add or remove a cube layer to adjust the depth. For optimal protection, maintain at least 25 mm (one inch) of foam between equipment and the case walls.
6. Reinsert the foam, load your gear, and close the case.

Key Specifications

• Compatible case: Peli Air 1535 Carry-On Case
• Material: Black polyurethane Pick N Pluck foam
• System: Pre-scored cube grid for tool-free customisation
• Colour: Black
• Part number: 015350-4000-000E
• Layers: Multiple depth layers included for full interior coverage

Why Replace the Original Foam?

Foam degrades over time. With regular use and compression cycles, even high-quality polyurethane begins to lose its resilience — cubes crumble, surfaces flatten, and the once-snug fit becomes loose. A worn foam set no longer absorbs shock effectively and can allow equipment to shift during transit. Replacing the foam restores the case to its intended level of protection and gives you the opportunity to re-layout the interior to match your current gear — not the gear you had when you first bought the case.

Using the genuine Peli replacement foam ensures the correct density, dimensions, and cube-grid specification for the 1535 Air interior dimensions. Third-party foam alternatives may not fit precisely, leaving gaps at the edges or forcing a compressed fit against the lid.