A Chicago-area startup designs and manufactures custom foam inserts for tool boxes, work stations, travel cases, and reusable packaging. Kaiser Manufacturing says its technology meets the demand for a custom solution that outperforms hand-cut foam in both functionality and appearance.
“The problem we solve for our customers is how to create custom foam inserts for their unique combination of tools and accessories,” said Nick Kaiser, operations manager. “No two shops have the same setup, so we brought in handheld 3D scanners to quickly digitize the entire toolbox layout.”
LED scanners can scan outlines or mock-ups of parts 24 x 48 inches or larger with accuracy down to 0.02 inches. The 3D file is converted to CAD and the design is machined onto two-color foam to accommodate each tool and place it in a specific workstation, box or drawer.
3D scanning kits are available for rent, with video tutorials, or as a turnkey service. This allows customers to conveniently scan their workshop tool layouts. There is no need to ship tools, download or license software, or purchase hardware. It also saves design time compared to designing a tool tray in-house, and the finished product looks more professional than hand-cut foam.
Kaizen Shadow Foam™ is a durable, closed-cell polyethylene material that does not accumulate dust, is resistant to oils, solvents, and is washable. It is a popular choice for lean manufacturing, 5S programs, and PPP prevention.
“Many companies invest in high-quality tools, gauges, and other equipment, but fail to protect that investment on the shop floor,” explains founder Chris Kaiser. “When expensive cutting tools, chucks, or tool holders are moved around in boxes, they can easily become damaged. Proper storage reduces damage and waste.”
This method of organizing tools has other benefits. Operators save time by finding tools without having to search for them. When all tools are neatly organized, the gear shifting process becomes smoother. Contrasting colors help create an intuitive workspace and highlight missing tools, thereby improving asset safety and reducing tool replacement costs.
A culture of continuous improvement, waste reduction and inventory minimization is adopted throughout the company and embedded into all aspects of the business.
Post time: Apr-03-2025