The Country Innovation & Supply Die-Cut Foam & Tool Control Resource Center is the index for choosing foam: which material for which job, what density and color to specify, where shadow boards and FOD control apply, and how to submit a layout so the first cut is the right one.
All foam is cut in the USA to your layout. See the product page or send us a layout.
Key Benefits
- Foam type comparison in one table, PE, cross-linked PE, EVA, ESD, and Kaizen
- Density and color guidance so tools sit where they belong and gaps are visible
- Application table covering tool cribs, shadow boards, case inserts, FOD, and 5S
- A clear layout submission path: drawing, CAD, photo, or physical sample
Foam Type Comparison
| Foam | Feel and structure | Best for | Watch out for |
|---|---|---|---|
| Polyethylene (PE) | Closed cell, firm, durable | Tool drawers, cases, general cushioning | Coarser cut edge than XLPE |
| Cross-linked PE (XLPE) | Closed cell, fine uniform cell structure | Presentation-grade inserts, clean cavity walls | Higher material cost |
| EVA | Softer, more resilient | Cushioning delicate items, comfort-critical inserts | Less rigid for deep narrow cavities |
| ESD foam | Conductive or anti-static | Electronics, PCBs, sensitive instruments | Specify the required surface resistivity |
| Kaizen foam | Layered, user-cuttable sheets | In-house layout changes, contrasting gap color | Not as precise as die-cut cavities |
Density and Color
| Choice | Guidance |
|---|---|
| Lower density | Lighter tools, more give, easier finger access around cavities |
| Higher density | Heavy tools, deep drawers, cavities that must hold shape over years |
| Two-color build | Dark top layer over a bright base so a missing tool is instantly visible |
| Common colors | Black, blue, red, yellow, green, and white |
| Finger reliefs | Add a scallop at each cavity so tools lift out without prying |
Applications
| Application | What it solves | Typical build |
|---|---|---|
| Tool crib and drawer inserts | Search time, missing tools, unclear ownership | Die-cut cavities, two-color |
| Shadow boards | Wall-mounted visual control at the point of use | Two-color panel, labeled cavities |
| FOD control | Foreign object debris in aerospace and precision work | High-contrast base, one cavity per tool, audit-ready |
| 5S and lean audits | Sustaining the standard after the kaizen event | Two-color foam plus location labels |
| Case and instrument inserts | Transit damage to instruments and equipment | Cut to case interior, cushion layer under cavities |
| In-plant handling trays | Damage while moving parts between operations | Cavity trays sized to the part |
How to Submit a Layout
- Send a tool list, a photo of the tools laid out, a drawing, or a CAD file
- Confirm the drawer, case, or board interior dimensions and usable depth
- Tell us the environment: oils, solvents, ESD requirements, temperature
- Approve the cavity layout and color build we return
- Reorder later from the same file for identical repeat sets
Next Steps
Request a die-cut foam quote with your tool list or drawer dimensions, or read the aerospace FOD control case study._Talk to a real person in minutes, no bots, no delays._
Related References
- Die-Cut Foams, product page with applications and FAQs
- Aerospace Supplier Eliminates FOD Risk, case study
- ISG Die-Cut Foam Case Study
- Protective Packaging, custom foam fabrication for transit
- Medical Device Protective Packaging Case Study