Project:Foam Inserts: Difference between revisions
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{{ProjectInfoBox | {{ProjectInfoBox | ||
|project title= | |project title=Shadow Boards | ||
|image= | |image= | ||
|status= | |status=Research | ||
|date= | |date= | ||
|initiator= | |initiator=Keno | ||
|team=[[Lmnl99]], [[Keno]], [[AlexBaumgart]], [[Jeddi]] | |team=[[Lmnl99]], [[Keno]], [[AlexBaumgart]], [[Jeddi]] | ||
|materials=[[ | |materials=[[PE Foam|PE foam]] | ||
|tools=[[Laser Cutter|laser cutter]] | |tools=[[Laser Cutter|laser cutter]] | ||
|software= | |software= | ||
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'''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. | |||
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== | == Materials: PE Foam == | ||
A popular material for producing shadow boards is '''closed-cell polyethylene (PE) foam'''. PE foam is lightweight, durable, and easy to cut precisely with a laser. | |||
== Cutting == | 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: | |||
# '''Tool Arrangement & Scanning''' Place the tools on a flat surface, photograph or scan them from above, and import the image into design software. | |||
# '''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. | |||
# '''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). | |||
# '''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. | |||
# '''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 == | == Results == | ||
Revision as of 09:43, 16 September 2025
| 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.
Materials: PE Foam
A popular material for producing shadow boards is closed-cell polyethylene (PE) foam. PE foam is lightweight, durable, and easy to cut precisely with a laser.
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.
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.
Laser Cutting Workflow
A general workflow for producing shadow boards with a laser cutter is:
- Tool Arrangement & Scanning Place the tools on a flat surface, photograph or scan them from above, and import the image into design software.
- 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.
- 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).
- 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.
- 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
<<<PHOTOS?>>>
