DeWalt ToughSystem 2.0 Deep Foam Insert

Why I reached for this foam

I wanted to tame the chaos in my ToughSystem 2.0 stack—one small box for a drill/driver kit, a medium for meters and clamps, and a deep tray for odds and ends that always seemed to migrate. The ToughSystem foam insert promised a simple, modular way to carve out homes for everything without committing to a full custom CNC job. After putting a few inserts to work across different boxes and the deep tray, I’ve got a clear sense of where it excels and where it asks for some patience.

What it is

This is a layered, black, high-density foam sheet designed for ToughSystem 2.0 boxes (small through XL) and the 2.0 deep tray. The insert comes as a single piece, roughly 12.4 x 19 inches and just over 3 inches thick, with a subtle laser-marked grid on the surface to guide layout and straight cuts. The foam’s lamination lets you control depth by peeling layers or by cutting and removing material in measured steps. You can stack multiple inserts if you want more height or mix and match to build custom tiers inside larger boxes.

There’s no pick-and-pluck perforation here—this is true cut-to-fit foam. Think kaizen-style workflow rather than cubed foam.

Build and design

The foam density is appropriate for hand tools, power tools, meters, and batteries. It’s firm enough to keep heavier items from shifting but not so rigid that it cracks when you make tight interior corners. The laser grid is subtle but genuinely helpful; it reduces wandering lines and keeps multiple cavities aligned when you want a neat presentation. The lamination is consistent, so depth control is predictable when you peel layers or cut to depth.

I did notice manufacturing variance at the outer edge. A few inserts had slightly concave perimeter cuts, trimming away some of the usable edge by roughly a quarter to a half inch on one side. It’s not catastrophic, but it’s enough that I plan cavities with a bit of margin and avoid relying on the last half inch of perimeter for support.

Fit in the boxes

The insert footprint is sized for the ToughSystem 2.0 floor dimensions, and it drops right into the small, medium, large, and XL boxes, as well as the deep tray. In my boxes, the fit was functional but not perfectly snug. Expect a hair of side-to-side play rather than a press fit. In the small box, I eliminated the rattle by adding a thin strip of 1/8-inch craft foam along one long side. In the deep tray, two inserts stacked neatly, and I trimmed corners to clear the tray’s side grips.

It’s worth noting there’s no matching foam panel or hardware for the lid. If you need top-side cushioning for delicate tools, you’ll have to add your own solution (a thin egg-crate foam pad or a DIY hook-and-loop panel works).

Customizing workflow

Here’s the routine that gave me the cleanest results:

• Blue painter’s tape over the surface makes tracing outlines and notes easy to see and remove.
• For cutting, a long, sharp snap-off blade or a dedicated kaizen knife is ideal. Use light, repeated passes rather than forcing a deep cut.
• To create a slight “press fit,” keep the blade angled inward a few degrees so the cavity tapers.
• For multi-level cavities (e.g., a drill body with battery), I cut the outline, removed one or two layers for the body, then traced and cut again for the battery profile to nest deeper.
• Label cavities with a silver marker on the sidewall or under the tape layer so tools return to the same spot.

The grid kept me honest, and the layered construction made depth control predictable. A compact drill/driver kit (driver, spare battery, charger, bits) took about 30–40 minutes to lay out and cut cleanly on my first pass. By the third insert, I was faster and more confident with tight radii.

Performance in the field

With a full day of jobsite hopping, the foam kept tools anchored and protected. Batteries stayed seated, small bits didn’t migrate, and the drill body didn’t abrade the cavity walls—even after plenty of box shuffling in the truck. The foam rebounds well after compression and hasn’t shed or pilled at high-contact edges. If you cut a proper taper and avoid slicing paper-thin bridges between cavities, it holds shape nicely over time.

Stacking worked as promised. In the deep tray, I used one layer for layout tools on top and a second layer for small electronics below. Lifting the top foam tray revealed the second tier without fuss. The layered approach makes it easy to reconfigure later, though it does mean you’re investing time with a knife rather than popping out pre-scored cubes.

What I’d change

• Perimeter precision: Slight concavity on the outer edge eats into usable space and looks sloppy in a box that’s otherwise well engineered. A tighter die cut would make a real difference.
• Snugness: I’d prefer a true press-fit perimeter, especially for the small box. It doesn’t need to be tight enough to bind—just enough to eliminate rattle.
• No lid option: A companion lid foam or adhesive-backed panel would round out the system for delicate gear like laser levels, sensors, or cameras.
• No pick-and-pluck option: Cut-to-fit gives the cleanest results, but for quick jobs, a perforated version would save time. Offering both styles would serve more users.

Tips to get better results

• Tape before tracing. The tape trick both improves visibility and protects the top surface from scuffs while cutting.
• Plan your margins. Leave at least 1/2 inch of foam between cavities and edges; more for heavier tools.
• Cut shallow and repeat. Multiple light passes keep corners crisp and reduce ragged edges.
• Taper intentionally. A slight inward bevel makes tools feel snug without crushing the foam.
• Test-fit as you go. Sneak up on the fit, especially with odd shapes or rubber overmolds that compress differently.

Value and who it’s for

If you’re already invested in the ToughSystem 2.0 ecosystem, this foam insert is a straightforward way to organize without leaving the platform. It’s especially good for users who want clean, custom cavities and are willing to spend a bit of time to get them right. For a drill kit, meters, batteries, small hand tools, and delicate electronics, the foam density is well matched.

If you’re looking for speed over finish, prefer pick-and-pluck convenience, or need a factory-smooth perimeter fit, you may find yourself wishing for a different approach. Likewise, if you need lid protection, plan on pairing this with a separate lid foam.

The lifetime limited warranty is a nice touch, though with foam, the real test is cut quality and long-term resilience. On both fronts, it’s performed well for me.

Recommendation

I recommend the ToughSystem foam insert to anyone organizing a ToughSystem 2.0 stack who values custom, tidy layouts and a durable, layered foam that holds up to daily use. It’s easy to work, dense enough for real protection, and flexible across boxes and the deep tray. I’d like to see a snugger perimeter, cleaner edges from the factory, and an optional lid panel, but those are refinements rather than deal-breakers. If you’re willing to do the cutting, the results are professional, repeatable, and a clear upgrade over loose tools rattling around a box.