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Scan-to-CAD Process for Custom Tool Foam Organizer

A start-up company near Chicago designs and fabricates custom tool foam inlays for toolboxes, workstations, travel cases and reusable packaging. Kaiser Manufacturing said its process fills the need for a custom solution that is superior to hand-cut tool foam in function and appearance.

"The problem we solve for our customer is how to create a custom foam inlay for their unique mix of tools and accessories," said Nic Kaiser, Operations Manager. "No two shops have the same set-up, so we introduced portable 3D scanners to quickly capture the layout for a full drawer of tools."

The LED scanner can capture a part profile or layout of 24" x 48" or more with an accuracy of 0.02". The 3D files are converted to CAD and the design is machined in two-color foam to nest each tool and fit the specific workstation, case or drawer.

The 3D scanning kits are available on a rental basis, complete with a video tutorial, or as a turn-key service. This makes it convenient for customers to scan tool layouts in their own shop. "No need to ship tools out, download or license software, or purchase any equipment. It also saves engineering time compared to designing tool trays in house, and the finished product is more professional than hand-cut foam," said a company spokesperson.

The two-color material, called Kaizen Shadow Foam, is a durable and closed-cell polyethylene that is dust-free, resistant to oils and solvents and can be cleaned. It is suited for lean manufacturing environments, 5S initiatives and for FOD prevention.

"A lot of companies invest in top-quality tooling, gauges and other equipment but do not protect that investment in the shop," explained Chris Kaiser, company founder. "When expensive cutting tools or collets or holders shift around in drawers, they are easily damaged. Proper storage reduces both damage and waste."

The spokesperson added, "There are additional benefits to this type of tool organization. It saves time when an operator can reach a tool without searching. Shift changes are smooth when everything is in its place. Contrasting colors aid in creating a visual workspace and highlight missing tools, which improves asset retention and reduces spending on replacement tools."

For more information contact:

Kaiser Manufacturing

396 E St. Charles Road

Carol Stream, IL 60188


IMTS West Building, Level 3

Booth 432149

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