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Buy Laminated Plywood and Foam Offcuts for DIY Road Cases
If you’re building your own road cases, you’re already ahead of the game. DIY means control over design, customization, and—most importantly—cost. But while you might be saving on labor, material costs can still sneak up on you. Full sheets of laminated plywood, EVA foam, and polypropylene panels are often the priciest items on your list. That’s where offcuts come in. At Armor Cases, we’ve turned leftover materials into a goldmine for DIY builders.
Purchasing Offcut Laminated Panel and Foam Material For Your DIY Road Cases and Save 35%
Every day, our workshop machine center cuts plywood sheets and foam sheets for road cases and flight cases productions. This process naturally produces offcuts. We keep any offcuts with a shorter side of at least 400MM to be reused by future productions. Most of the offcuts are quite big and can be used for building large sized road cases. These offcuts are stored in our dedicated rack and tracked in our Offcut Management System, making them easy to be searched and consumed. We are now making this system available for our customers to browse and purchase.
Available types of offcuts:
- EVA and EPE foam offcuts for case internal padding, or tool case foam insert.
- Laminated plywood and flight panel offcuts for case shell
- Carpet offcuts, good for tool box lining, van cargo walls lining, etc.
These materials are the same high quality we use in our full-size cases—just smaller and more affordable.
How Offcut Pricing Works
And here’s the best part: offcuts are sold at a 35% discount compared to full sheet of the same area. We calculate offcut prices based on their area compared to a full sheet. The price of an offcut plywood or foam is 35% less compared to a full sheet with the same area or size:
(Area of offcut ÷ Area of full sheet) × Full sheet price × (1-35%)
For example, our full sheet of laminated birch plywood 12.5MM is 2440X1220MM in size, and as of 2025 it costs $173.25+gst. An offcut that is approx. 610x1200MM has an area of approx. 1/4 of that of a full sheet. The price of this offcut is
1/4*173.25*(1-0.35)=28.15.
If you buy 4 of this offcuts, you have the same amount of plywood by area compared to a full sheet, but you are paying 28.15*4=112.6+gst, which saves you about 60+gst. We do have quite a lot of offcuts of decent sizes and you won't be limited to building just tiny cases. That’s serious savings—especially when you’re building multiple cases or experimenting with new designs.
Here’s another hidden benefit: offcuts are cheaper to ship. Full sheets are bulky and will always requires 2 pallet space in a freight truck being 2440MM long. Offcuts, on the other hand, are compact and which means they cost less in shipping, are easier to handle. The same offcuts in the above example, occupies only 1 pallet space in a truck so shipping cost is halved. For customers who cannot pickup from our warehouse, shipping offcuts usually means saving between 100 to 200 dollars of shipping cost depending on your location. In fact, to most interstate customers, the cost of shipping large sheets can often exceed the cost of the sheet material themselves.
How to Buy Panel and Foam Offcuts from Armor?
Just visit our Armor Case Management System, where you can:
- View available offcuts by material type
- Check dimensions, availability and prices
- Screenshot the items that are suitable for your need and send them to us via email to confirm availability.
We made a walkthrough video below to help you with the browsing and ordering process.
Foam and Panel Offcuts with Smaller Sizes Less than 400MM are Free!
For offcuts that are less than 400MM in size, unfortunately due to economic reasons, they are going to our waste bins. These offcuts are completely free. These smaller offcuts are good for generating the smaller parts for a road case such as the side panels of a cable packer lid, or speaker case base. They are also large enough for building smaller cases such as record cases, or other smaller road cases. To be clear, an offcuts measures 390x1220MM falls in this category and is free.
The same is true for our EVA and EPE foam offcuts. Smaller pieces have to be binned but they often have various use even outside the case building application. They are useful for heavy duty packaging and insulation.
If you have long term needs of such offcut material, we can work with you to accumulate and sort the different types of offcuts for you and arrange scheduled pickup. This helps to save our environment by having less of them going to landfill.
Build Smart, Save Big, Save Environment
Offcuts aren’t just leftovers—they’re opportunities. With Armor Cases’ offcut system, you get premium materials at discounted prices, reduced shipping costs, and the flexibility to build exactly what you need.
Whether you’re a seasoned road case builder or just starting out, offcuts offer a smarter, more sustainable way to create. So next time you’re planning a build, skip the full sheets and explore our offcut rack first. Your budget, your back, and the planet earth, will thank you. If you cannot find offcuts sizes that are suitable for your needs, then you can order full sheets from our laminated plywood panel and EVA and EPE foam product categories.