Shadow boards and foam inserts – Customized organization systems for tools and more

Everything has its place, is safely and clearly stored, and missing items can be identified immediately – multi-colored shadow boards are the heroes of storage. Whether in tool cases and drawers or as protective packaging for cameras, microphones, or drones, the foam inserts made from high-quality materials are used across a wide range of products and industries. The goal: efficiency in the workplace by avoiding waste.

Although the idea of customized shadow boards actually comes from tool organization in aircraft engineering, it has also proven itself in production and everyday life. With the help of recesses that are optimally matched to the respective tools, for example, open-end wrenches, screwdrivers, and pipe wrenches always have their fixed place. This not only ensures order and cleanliness, but also makes missing parts immediately visible thanks to the multi-colored foam of the tool insert. What appears to be a purely visual design decision quickly became established in aircraft engineering. And for good reason: as soon as something is removed, the empty space stands out from the mostly gray or black foam thanks to its signal color. This means that missing tools can be quickly identified and replaced. Thanks to the individual foam inserts with the colored base, potential sources of danger can be avoided, as can unnecessary waste of resources (e.g., searching for tools). The customized shadow board thus contributes significantly to lean management in a company.

Lean management – an excursus

Lean management aims to make the workplace more efficient by creating a holistic production system without waste. To this end, all processes and activities are coordinated in such a way that any kind of waste, e.g., in the form of unproductive search times for missing, desired tools, is avoided along the value chain. This process optimization is reflected in lower product prices for the customer.

Versatile application possibilities for foam inserts

However, the use of foam shadow boards is not limited to tool inserts, but can be applied to many products. In contrast to solid molded inserts, single or multi-colored shadow boards are manufactured without a mold. This means that no costly, specially manufactured tools, e.g. made of aluminum, are required to produce the foam inserts. All you need for the shadow boards is a CAD program, which can be modified quickly and inexpensively as required. This becomes necessary if the geometry of the insert has to be changed, e.g., due to new tools or changed dimensions of the drawer or case. This means that everything can always be transported and stored safely – from the drone and camera to the tools.

Our shadow boards – combinable and customizable

We mainly use PE foam materials and cut-outs to manufacture our shadow boards. These are available in numerous intense colors and different qualities, which can be combined as desired and assembled into multi-colored foam inserts. In combination with our surface finishing options (e.g., EVO//TOUCH and EVO//FOIL for a pleasant feel), there are no limits to your creativity when it comes to customization. For your very own personalized shadow board!

Advantages of shadow boards at a glance

• fixed allocation of space
• Quick identification of missing parts thanks to optimal overview
• Cleanliness in the workplace
• safe storage
• Safe transport
• customizable
• cost-effective shape adjustment

Would you like to purchase a shadow board? Then get in touch with us!

Efficient tool organization: Foam tool inserts offer many advantages!

A well-organized workshop is the key to greater efficiency and productivity. Foam tool inserts, also known as shadow boards, offer innovative solutions for creating order and optimizing workflows. We have summarized the advantages of shadow boards below.

A common problem in workshops is clutter and time-consuming searches for the right tool. Foam tool inserts provide clear, visual organization where every tool has its place. The precisely fitting recesses in the multi-colored shadow boards make missing tools visible at a glance, which greatly facilitates traceability and inventory management.

Time savings and increased productivity

The efficiency of a work process often depends on the time needed for preparation. With foam tool inserts, there is no need to search for the right tool, as each one has its own fixed place. This allows employees to spend their time on the actual work instead of searching for tools, which leads to an increase in overall productivity.

Protection of tools

Tools are often expensive and sensitive to damage, and tools lying around loose can easily become worn or damaged. Shadow boards provide a padded surface that absorbs shocks and vibrations during transport or storage. This helps to extend the service life of the tools and reduce the need for replacement purchases.

Ergonomics and safety

The arrangement of tools on shadow boards can also offer ergonomic advantages. By placing tools in easily accessible locations, employee posture is improved and physical strain is reduced. This can lead to a reduction in fatigue and injuries in the workplace, which ultimately promotes employee health and safety.

Customizable solutions for different needs

A major advantage of customized shadow boards is their adaptability. The foam inserts are cut to size to meet specific tool and workshop requirements (link to Hans Peter Esser article). This allows for optimal tool organization and efficient use of available space.

Efficiency through order

Foam tool inserts, shadow boards, offer an innovative, effective, and customizable way to organize workshops of all kinds. The advantages range from improved cleanliness in the workplace through the creation of order and clarity to increased productivity, tool protection, ergonomics, and safety. The customizability of the shadow board to the existing tools makes it an attractive choice for anyone who wants to optimize their workflows and increase efficiency.

If you are interested in making your workplace tidier, safer, and more efficient, please do not hesitate to contact us.

Foam tool inserts: The optimal solution for transporting tools

Efficient tool transport is crucial in many industries in order to save resources and get tools safely to their destination. Foam tool inserts, for example in the form of two-color shadow boards, offer an ideal solution for optimizing tool transport.

Transporting tools can present a number of challenges, including the risk of damage, loss, and disorder. This is because loose tools in cases, boxes, or bags can slide around during transport and damage each other. Foam tool inserts that are precisely tailored to the respective transport container can help solve these problems.

Secure hold thanks to customized foam inserts in every industry

Customized tool inserts offer a tailor-made solution for keeping tools of various sizes secure and stable during transport. The foam inserts can be manufactured to reflect the exact shapes of the tools. This creates a perfect fit that prevents the tools from slipping or rolling around. This customized approach offers optimal protection, significantly minimizing the risk of damage during transport. Another major advantage of foam tool inserts is their flexibility. The fact that the inserts can be adapted as required to safely transport differently shaped tools or devices makes them an ideal solution for every industry. (Link to customer projects)

Protection against damage

Tools transported in rigid or poorly fitted inserts can easily be damaged by impact or vibration. Foam tool inserts provide soft yet durable padding that effectively absorbs these impacts. This minimizes the likelihood of damage, which not only extends the service life of the tools but also reduces repair or replacement costs.

Efficient tool transport thanks to customized solutions

Foam tool inserts, such as two-color shadow boards, offer an optimal solution for the efficient and safe transport of your tools. The customized tool inserts ensure that the tools are held securely in place, while clear organization and protection against damage increase the reliability of transport. Whether in the workshop or on construction sites, the use of foam tool inserts contributes to optimum protection during tool transport.

If you are interested in storing and transporting your tools more safely, please do not hesitate to contact us.

Proper care of shadow boards and other foam tool inserts: tips and tricks

To ensure that your foam tool inserts remain ready for use, clearly arranged, and intact, you should follow a few important care tips.

Foam tool inserts and shadow boards are indispensable aids when it comes to maintaining order and efficiency in workshops, garages, or laboratories. Not only do they provide a safe storage option for tools and equipment, but they also help to extend their service life. To ensure that your foam tool inserts remain ready for use, clearly arranged, and intact, we have put together a few care tips for you.

Cleaning and care:

1. Dry cleaning your foam tool inserts helps remove dust, dirt, and oil residues. Use a vacuum cleaner, soft brush, or compressed air at regular intervals to remove loose particles.

2. If more thorough cleaning is required, use mild soap solutions or special foam cleaners. Soak a soft cloth in the solution and gently clean the surface of the tool insert. Be careful not to use aggressive cleaning agents, as these could damage the foam, and make sure the insert is completely dry before placing your tools back on it.

3. Foam can absorb liquids, which can lead to deformation and damage. Therefore, keep liquids away from the tool inserts and clean up any spilled liquids immediately.

Storage:

1. Store your tool inserts in a dry and clean place to prevent moisture and mold growth. Moisture can damage the foam and impair the integrity of the tool insert.

2. Foam is highly durable, but extreme temperatures can also affect it. Avoid excessive heat or cold to prevent deformation or cracking.

Overall, proper care of foam tool inserts is an important factor in ensuring longevity and functionality. With regular cleaning and careful storage, you can ensure that your shadow boards will serve you reliably for a long time – for a tidy workshop.

 

Are you interested in a tool insert? Don't hesitate to contact us.