Custom Die-Cut Foam Inserts & Tool Shadow Boards
Foam inserts for tool drawers, shadow boards, and equipment cases, cut to your tool list, photo, CAD file, or physical sample. From Country Innovation & Supply in Winder, Georgia. All foam is cut in the USA.
PE, XLPE, EVA, ESD, and Kaizen foam | Reorders cut from your approved file
Specialty Die Cut Foams
Foam that fits your tools, your drawers, and your cases
A good foam insert does three jobs. It gives every tool one place to live, it makes a missing tool obvious at a glance, and it keeps parts and instruments from getting damaged in a drawer, on a cart, or in a shipping case.
CIS cuts custom foam inserts and shadow boards to your layout. Send us what you have, a tool list, a photo of the tools laid out, a drawing, a CAD file, or the tools themselves, and we return a cavity layout and color build for you to approve before anything is cut. Once approved, we keep the cut file so the next set matches the first.
We can also kit your product into the foam and case. See kitting and co-packing.
What we make
Tool drawer and tool crib inserts. Die-cut cavities for each tool, usually in a two-color build so an empty cavity shows.
Shadow boards. Wall-mounted foam panels at the point of use, with labeled cavities for quick audits.
Case and instrument inserts. Foam cut to the inside of your case, with a cushion layer under the cavities for transit protection.
In-plant handling trays. Cavity trays sized to the part, for moving parts between operations without dings and scratches.
Shipping inserts. Custom foam inserts and sheets for products that need more than void fill. For full transit packaging programs, see Protective Packaging.
Kaizen foam. Layered, user-cuttable foam for areas where layouts change often. Many teams start here and move to die-cut once the layout settles.
How a custom foam project works
- Send what you have. A tool list, a photo of the tools laid out on a flat surface, a drawing, a CAD file, or a physical sample. Photos are fine to start.
- Confirm the space and the environment. Give us the inside dimensions and usable depth of the drawer, case, or board, and tell us what the foam will be around: oils, solvents, ESD requirements, temperature.
- Approve the layout. We return a cavity layout and color build. Nothing is cut until you sign off.
- Production. Foam is cut to the approved layout.
- Reorder without starting over. The approved cut file is kept on record, so repeat sets match the original.
Which foam is right for the job
| Foam | What it is like | Best for | Keep in mind |
|---|---|---|---|
| Polyethylene (PE) | Closed cell, firm, durable | Tool drawers, cases, general cushioning | Coarser cut edge than XLPE |
| Cross-linked PE (XLPE) | Closed cell, fine and uniform | Presentation-grade inserts, clean cavity walls | Higher material cost |
| EVA | Softer, more resilient | Cushioning delicate items | Less rigid for deep, narrow cavities |
| ESD foam | Conductive or anti-static | Electronics, PCBs, sensitive instruments | Specify the surface resistivity you need |
| Kaizen foam | Layered sheets you cut yourself | Layouts that change often, contrasting gap color | Not as precise as die-cut cavities |
For oily or greasy tools, choose closed-cell PE or XLPE. Both resist oil and wipe clean. Open-cell foam soaks up contaminants and breaks down.
Full comparison, density guidance, and layout tips in the Tool Control Foam Guide.
Density and color
- Lower density gives more give and easier finger access. Good for lighter tools.
- Higher density holds its shape for heavy tools and deep drawers.
- Two-color builds put a dark top layer over a bright base, so an empty cavity stands out.
- Colors: black, blue, red, yellow, green, and white.
- Finger reliefs: a scallop at each cavity lets tools lift out without prying.
Die-cut foam, Kaizen foam, or vacuum-formed trays?
- Die-cut foam is the usual choice for tool control and FOD programs. It cushions well, tooling cost is low, and layouts are easy to revise.
- Kaizen foam makes sense while a layout is still changing, because your team can cut it in-house. Move to die-cut once the layout is stable.
- Vacuum-formed trays win at very high volume and where washdown durability matters.
Who we cut foam for
Tool crib and maintenance teams
Drawer inserts and shadow boards that cut search time and show missing tools.
Quality, lean, and 5S leads
Two-color foam plus location labels to sustain the standard after a kaizen event.
Aerospace and precision work
One cavity per tool on a high-contrast base for FOD control.
Packaging engineers
Case inserts, instrument inserts, and shipping inserts cut to the product.
Production and assembly
In-plant handling trays that protect parts between operations.
We work with automotive, electronics, defense, medical, and industrial customers.
Need tool IDs or cavity labels? Pair foam with durable industrial labels.
Based in Winder, Georgia
Country Innovation & Supply is based in Winder, Georgia, northeast of Atlanta. Call 770-561-5285 or request a quote.
Tool Control Foam Guide
Foam type comparison, density and color selection, shadow boards, FOD control, and how to submit a tool layout.
Aerospace Supplier Eliminates FOD Risk
Discover how an aerospace components supplier transformed their tool and parts organization with custom die-cut foam solutions, achieving FOD compliance and efficiency gains.
Have a drawer, case, or board that needs foam?
Send a photo and the inside dimensions. We will come back with a layout.
Request a Foam Quote
