Peli Air 1646 Replacement Foam Set

The Peli Air 1646 is one of the lightest large-format protective cases on the market, trusted by photographers, videographers, and field professionals who need gear to arrive intact — every time. Even the toughest outer shell is only as good as the protection inside. Foam compresses over years of use, loses its cushioning properties, and stops holding equipment securely. This is the official Peli replacement foam set, precision-matched to the exact interior dimensions of the 1646 Air case.

Whether you're equipping a brand-new 1646, renewing the interior of a well-used case, or repurposing a second-hand one for different equipment — this set gives you everything needed to create a snug, custom-fitted interior from scratch.

How the pick-n-pluck system works

The foam layers arrive pre-scored in a grid of small cubes — no cutting tools required. Place your gear on the foam, trace the outline, and press out the cubes by hand. The result is a perfectly contoured recess for every piece of equipment. Cameras, lenses, drones, audio recorders, medical instruments — each item held exactly in place, not shifting when the case is loaded into a cargo hold, dropped off a vehicle, or bounced along a rough trail.

Important: always leave at least one centimetre of foam between your equipment and the case walls. That margin absorbs lateral impact and prevents gear from shifting under stress.

What's included

The set covers the full interior of the Peli Air 1646: a pre-scored pick-n-pluck layer for custom equipment recesses, plus foam for the lid and the base. All foam is black, does not yellow over time, resists petroleum-based products, and does not absorb moisture — keeping the interior clean and functional for years.

Who it's made for

• Photographers and videographers carrying multiple camera bodies, lenses, and accessories
• Drone operators protecting UAV frames, batteries, and control hardware
• Audio engineers transporting microphones, preamps, or field recorders
• IT and field service teams deploying sensitive electronics
• Scientists and technicians carrying calibrated instruments or fragile samples

The Peli Air 1646 in context

The 1646 sits at the top of the Peli Air line — a large-format, wheeled rolling case engineered for professionals who travel regularly and work within airline weight limits. Peli Air cases weigh significantly less than comparable protective cases while maintaining the same resistance to drops, crush, and water. A foam layout matched to your exact equipment turns an excellent case into a complete system — and it starts here.