Project:Foam Inserts

ProjectInfoBox Shadow Boards
Status:	Research
Initiator:	Keno
Team:	Lmnl99, Keno, AlexBaumgart, Jeddi
Materials Used:	PE foam
Tools Used:	laser cutter

Foam inserts, often called Shadow boards are organizational boards used to store and display tools or equipment in clearly designated locations. They are commonly used in manufacturing, workshops, laboratories, and maintenance environments to improve organization, enhance safety, and support lean 5S workplace practices. Each tool has a fixed position marked by a silhouette or “shadow,” allowing users to quickly see if something is missing. They are typically made from closed-cell foam sheets that are precisely cut with a laser to create snug cavities for each tool. The two most commonly used materials for this purpose are EVA (ethylene-vinyl acetate) foam and PE (polyethylene) foam.

Each of these materials has distinct mechanical and visual properties that make them suitable for different design priorities in shadow board construction, such as tool protection, aesthetics, weight, and durability.

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EVA Foam

EVA foam is a soft yet durable closed-cell foam known for its rubbery flexibility and smooth appearance. The vinyl acetate content gives EVA a characteristic softness and elasticity that many other foams lack.

This material is widely used not only in yoga mats, cosplay costumes, and packaging, but also in precision-cut foam inlays where visual appearance and impact protection are important.

Key Properties of EVA Foam in Shadow Boards

• Soft and flexible – The smooth, rubbery texture offers excellent cushioning for delicate tools and protects surfaces from scratches.
• Highly durable – Resistant to tearing and compression, EVA retains its shape after repeated tool insertion and removal.
• Excellent shock absorption – Its elastic structure absorbs impacts from dropped tools, helping to protect expensive instruments.
• UV and weather resistant – EVA tolerates outdoor or workshop environments without degrading, making it suitable for mobile tool boards.
• Smooth, glossy surface – Provides a clean, professional finish that enhances the visibility of tools against the background.

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PE Foam

PE foam is another closed-cell foam, generally stiffer and firmer than EVA. It is valued for its high strength-to-weight ratio.

Key Properties of PE Foam in Shadow Boards

• Firm and rigid – Provides structural support to the board and prevents sagging over large tool areas.
• Lightweight – Despite its strength, it adds very little weight to wall-mounted or portable shadow boards.
• Excellent chemical resistance – Resistant to oils, solvents, and other shop chemicals, making it durable in industrial environments.
• Superior thermal insulation – Helps protect temperature-sensitive tools stored in unheated spaces.
• Cost-effective – Often a more economical choice for large boards or high-volume tool storage systems.

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EVA vs. PE Foam: Comparison for Laser-Cut Shadow Boards

Please note that the table below has been compiled based on claims by different manufacturers and may be optimistic about properties.

Property	EVA Foam	PE Foam	Better Option for Shadow Boards
Durability & resilience	Excellent – tear-resistant, high shape recovery	Good – strong but may crack under heavy stress	EVA for long-term, repeated use, but may not make a difference in shadow boards
Softness & cushioning	Excellent – soft, rubbery texture, protects delicate finishes	Moderate to good – firmer and stiffer	PE will hold tools in place better
Shock absorption	Excellent – absorbs impact energy	Very good – protects and braces stored items	No significant difference for shadow boards
Cost	Moderate	Lower – generally more affordable	PE for budget-conscious projects
Weight	Lightweight	Extremely lightweight	PE for large wall-mounted boards
Thermal insulation	Good	Excellent	Not relevant
Appearance & finish	Smooth, glossy, often vibrant color	More textured, matte surface	EVA for clean, high-visibility tool layouts

Overall, it seems that PE is the prevalent material for Shadow boards. However, statement is not quantified. To achieve the shadow effect, many users stack two contrasting layers of foam (for example, black on top of yellow). When the top layer is cut out to match tool shapes, the bright bottom layer becomes visible, highlighting the tool outlines.

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Design and Layout

Before cutting, a layout of the tools must be created. Digital layout tools help arrange silhouettes for efficient use of space. For example, ToolKaiser is a software tool that allows users to photograph their tools, trace outlines, and export the resulting vector files for laser cutting.

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Laser Cutting Workflow

A general workflow for producing shadow boards with a laser cutter is:

1. Tool Arrangement & Scanning Place the tools on a flat surface, photograph or scan them from above, and import the image into design software.
2. Vectorization & Layout Trace the outlines into vector paths (e.g., DXF or SVG format) using software like ToolKaiser or a vector graphics editor. Arrange the outlines on the virtual sheet matching the size of the foam.
3. Laser Preparation Choose PE foam sheets in two contrasting colors. Place the top layer in the laser cutter. Set cutting parameters appropriate for the foam (low power, high speed, multiple passes if needed).
4. Cutting & Assembly Cut out the tool silhouettes from the top foam layer. Adhere this cut layer onto the contrasting bottom layer using spray adhesive or double-sided tape.
5. Finishing Mount the finished foam shadow board into a drawer, tool chest, or onto a wall panel.

Notes

• This article is based on preliminary research and should be treated as a general overview rather than a complete manufacturing guide.
• Please make sure the foam is safe to cut. It is usually a good idea to source PE foam from Europe in order to avoid being in the dark about potential additives.

Results

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Further Reading

• nachdenksport.de - Werkzeugeinlage für Messinstrumente
• mimowork.com - Laserschneiden von Schaumstoff