Our Process Ensures a Perfect Fit and Professional Look Every Time
Work Directly with a Foam Expert to Plan and Execute Your Project
Our process begins with a conversation. Please feel free to contact us today.
When you are ready to begin a project, the first step in our custom foam process is to obtain accurate digital representations of your tools or items. There are three main ways that we do this:
OPTICAL SCANNING
Our unique and proprietary multi-dimensional optical scanner uses a combination of red and white light technology to obtain dimensionally accurate digital files of your tools, parts, or just about anything else you would like to place in a foam insert. Our scanner has been specifically engineered and developed to accurately handle complex, shiny, reflective, and translucent objects. Optical scanning is performed by a technician in-house at our facility. You may either bring your items in for scanning or opt to ship them to us. Optical scanning directly interfaces with our tool library and layout software and is the best choice for professionals looking to obtain extremely accurate pocket sizes for their foam inserts.
MOBILE IMAGING
We understand that bringing or shipping your items to our facility is not always possible. For these situations we have developed a mobile solution that accommodates most handtools and small objects. We can send a technician to your location to obtain images using our lightbox technology, which directly interfaces with our proprietary tool library and layout software, ensuring the best accuracy for a mobile solution. Alternatively, we can ship you a specially designed gridsheet and instructions on how to take photos of your items with either your digital camera or smartphone. While not as accurate as optical scanning, these mobile solutions generate sufficiently accurate results for most handtools and small objects.
CAD & MANUAL ENGINEERING
For a number of reasons, we prefer to scan the actual objects going in your foam inserts. In the rare cases in which your items are too large to be scanned or imaged, our team of engineers is fully equipped with the latest in CAD technology and can accept industry standard 3D file types (preferable) or detailed CAD drawings with all applicable dimensions. Absent sufficient dimensional drawings or files, you may bring or ship your items to our facility where an engineer will measure and build a 3D computer model of your items in SolidWorks. From these models we will develop a foam solution around your items in CAD.
We Use CNC Technologies that Deliver Repeatable World-Class Results
Our CNC equipment is built to handle production level jobs with speed and accuracy.
CNC ROUTING/MILLING
State of the art machinary that delivers unparalleled precision & accuracy
After our engineers design your foam inserts and you have approved the designs, we program our CNC (Computer Numerical Control) routers to cut your project. Our machines are designed to accommodate custom foam inserts of all shapes and sizes and are accurate down to the millimeter. We can cut single inserts up to 79’’ x 39’’ x 4.25’’ at a time. Because our inserts are CNC routed, we are able to create 3-dimensional, multi-step pockets that support your tools or sensitive equipment evenly and keep them level in the pockets. When dealing with items that require deep inserts, the precision of our CNC routing allows us to cut multiple layers of foam and stack and glue them together for a near seamless fitting end result.
CNC LASER SERIALIZATION & BRANDING
Eye catching branding & identification
Inventory management is a crucial requirement for many of our professional customers. Our Epilog Fusion laser engraver can engrave part numbers, serial numbers, identification codes, or personal information directly into your foam inserts (above). We can also laser engrave and cut colored plastic Part in Pocket (PIP) labels and adhere them into specially cut pockets in the foam to give added contrast and readability to your inventory management strategy (bot. left). Additionally, branding or personalization provides value for almost all of our customers. We have developed a number of various techniques to achieve eye-catching results that make your logo pop. All we need is a vector file (AI, CDR, EPS, etc.) of the artwork and we can engrave directly into the foam (bot. center) or use a combination of routing and engraving (bot. right).
