An example of what co2 laser can do is tool shadowing. I've used it myself to line camera boxes I've made, and it works really great, and can be laser cut.I don't know about "tool box foam" as you point out, but sometimes it's well worth it to spend a few bucks extra to protect your tools instead of taking the cheap route. PE should be fairly low outgassing, and in most applications for storing tools like these should not be an issue. By the 3rd try, the kerf is pretty tight. FWIW I agree with you about Adobe's pricing model. It might work...VHB tape is miraculous stuff. Creative applications, such as souvenirs and photo frames, are also a great use for laser-cut foam. Both of these types of foam are okay to cut on the Epilog laser at TechShop SJ. The laser easily cuts through a variety of foam thicknesses allowing you to precisely cut inserts that fit your specific tools. Question Ceramic based foam is not usually cut with a laser because it is very brittle and can crack. There's a class of plasticizers called pthalates that are particularly controversial right now with respect to their health effects. Shadow Foam allows you to quickly and efficiently create spaces for each tool. By the time you buy enough to layer up a reasonable thickness and a can of 3M Super 77 spray adhesive to hold it all together, the cost is crazy high. If the answer is "not very deep", maybe cutting the thinner materials like I used in this project as individual layers and then laminating them together could work. (585mm) square. Thanks for the kind words and the comment. I don't use their products anymore. This week we're laser cutting foam to create foam inserts forour industrial tools. Foam can be used for different applications so it’s one of the most versatile materials to work with for a do-it-yourself project. Who desired an easy to find, easy to use source for tool foam, tool control foam, foam for toolboxes and custom cut toolbox foam. 1-800-225-1066. Did you make this project? Test, test, test before committing your good material. I didn't really think the Kaizen foam would work best for you, but more for people who are not neat one of the shops where you can use the tools, like me, who may want to do something similar using a razor knife rather than a laser cutter. It didn't meet my basic cheapness criteria for this project because I didn't need the thickness. Universal Laser Systems logo and name are registered trademarks of Universal Laser Systems, Inc. All other company and product names are trademarks or registered trademarks of their respective companies. It takes a lot of time to measure and draw more complex outlines. Some people get very "sensitive" when comments appear to lead in a direction away from the Instructable, so I always "proceed with caution! For the purpose of cutting foam, the industry has discovered the laser beam as tool more and more frequently. We don't want PVC in the laser cutter due to the hydrochloric acid vapors produced during cutting. The highest price per sheet is 19.99 for the 57mm, and starts at $9.99. Please PM or email me when you get it and let me know what it looks like, and how it may work with a razor knife, maybe a pic or 2. I went on a hunt for other, less expensive sources for the same stuff. Too much oomph. A wide bottom-side kerf likely results from one or both of two causes: too much energy into the cut and/or the optics of the laser. Using inserts in tool boxes to protect and organize tools is called "shadowing" in the aerospace industry. It's almost impossible to keep track of lots of different recipes without notes. The whole point here is safe, long term storage. No rocket surgery here. The usual way to make close fitting DIY inserts around complex shapes is to trace the outline directly on to the foam with a Sharpie and cut out the recess by hand with an Xacto knife or scalpel (there are lots of YouTube videos on the subject). Learn how we shadowed a wrench set for easy storage and organization in tool… The carpet covered tile worked okay, but it's thin and more expensive than the other materials I tested. Open cell foams can be compressed easily because the air can flow freely through the pockets. Start with an organized toolbox. I hope you find this as useful as I found it fun to do. Where did you find 1/2" Plastizote for ~$4/sq.ft. The marker is good up to about an inch (25mm) and the lead holder is good to 2+ inches (50mm+) as long as you are careful to not break the lead as you trace. Thanks for this - your materials research was a great jump-start and saved me both time and money.I've tested the Walmart Ozark blue foam, and I find that on a through-cut the kerf becomes very wide at the bottom - is the fix for this to use less power and slower speed? I moved to the UK shortly after I needed it, so I didn't really have time to order it in the states, which led me to order it in the UK instead, from Thames Valley Supplies. Tim was in the middle of making something super cool out of this kind of foam at TechShop SJ when I stopped by to pump him for info. Thanks Tom. Pthalates are (or at least were) widely used in PVC. Looking at the stuff, it seems like some sort of polyolefin (polyethylene or polypropylene or a blend) which would cut fine on the laser. Not counting them, the tiles are actually less than 23 in. Call it $0.67/sq. Even if the exact material isn't listed, you might find something close enough to get you started. Minimizing the energy from where you are today could come from either increasing speed, decreasing power, or both. Our laser processing systems transform images or drawings from your computer screen into real items made out of an amazing variety of materials…wood, plastic, tile, fabric, paper, glass, leather, stone, ceramic, rubber and many more. To cut the foam is a different story to cutting wood but also requires the right supplies for the task. How to Make Charcuterie Boards Using Clear Acrylic Templates. A 9 in. We specialize in laser cutting custom layouts for foam. For the 60W Epilog laser at TechShop SJ, I used vector mode at 20% speed, 60% power, and 1000Hz. ft. You can't get this online, so you'll have to grit your teeth and go there. CNC-cut foam can be tens of times more expensive. Also, for reasons which should be obvious, you want to choose foams which are not in any way absorbent to make it easier to keep your tools in tip top shape. Toolbox foam Inserts. I also cut some long test slots for rulers in this material. As you say, outgassing is a problem with some plastics. Most stuff sold as "tool box foam" is polyethylene (PE) or ethylene-vinyl acetate (EVA) and is way too expensive. Home ... Tool Foam Blanks. I've found two tools that make it easier to trace. on Step 10. I've used this foam before and it cuts great in TechShop SJ's Epilog laser. Lens – A 2.0 lens is the best general process lens for foam laser material processing.Cutting Table – Supports sheets of foam for laser cutting.Exhaust – Must have sufficient flow to remove the gasses and particles that are generated during laser process from the foam laser engraving, cutting, and marking equipment.Air Assist – Provides a jet of air near the focal point of the laser to help remove gasses and particles that are generated during foam laser engraving, cutting, and marking. Any constructive criticism in the comments will be gratefully accepted. If you don't mind the cosmetic defects in the surfaces, it's pretty much the same as Harbor Freight's EVA tiles, only thinner. This method is practical for tools with simple outlines like 1-2-3 blocks, V-blocks, squares, and the like. It's good to hear that people are still finding this useful. (~610mm x ~1825 mm x ~13mm) for $7.97. Adobe's switch to a subscription only model for their products doesn't really work for me as a casual user. I started designing the tool layout by taking photo of the tools in place along with a ruler for scale. Bad for you and bad for the machine. The best results I achieved were at 4 passes of 65% speed, 60% power, 1000Hz, but that's not saying much. The advantage of using laser technology is that the pieces are cut perfectly, down to the last millimeter and in a well defined shape. The 1.06 micron wavelength is the best choice of cutting, engraving, and marking metal foam. I agree that for particularly delicate instruments or those that are hard to clean, it's best to err on the side of caution and get pay up for foam that does not outgas. Go 90 degrees, especially if you plan on flipping the foam over. For the 60W Epilog laser at TechShop SJ, I used vector mode at 35% speed, 60% power, and 1000Hz. ... We give you all the tools and instructions required to create efficient layouts. (~230mm x ~305mm) piece is about $1. Remarkably, some of these came with no protective container. I was going to get some, but the supplier I went to was out, and I've been focused on other projects ahead of it, but will be excited to hear how it actually works from someone I know. Kaizen foam looks very useful if you need something really thick. Inkscape also has an excellent raster to vector tool and is very useful. My foam cutting journey proves that there is no reason to pay the outrageous prices for "tool box foam" that is sold for that specific purpose. In open cell foams, the pockets are interconnected and filled with air. I ended up just unrolling it in the bed of my pickup truck (which happens to have black bed liner), putting some small weights on the ends, and letting it bake in the sun for a couple of hours. Beyond the general rules that slower speed or higher power takes more material and low frequencies are good for materials that char while high frequencies are good for things that melt, its largely a matter of trying some combinations to see what you get. Instead, each pocket is completely surrounded with solid material. To make inserts, we need foam, vector artwork of the tool outlines, and a recipe for cutting the foam. was enough. Things like the condition/age of the laser tube, how clean the optics are, etc. Organize your toolbox using durable foam inserts CNC-cut to shadow your tools. Sheet size: 2' x 4' (+ or - 1"). ft. I have found a source of foam in a neighbor who operates a vehicle upholstery business. Be sure to take notes while you are testing. BobsCNC E4 Router Engraver Kit with Router Included. Foam Cutter, Electric Hot Knife Styrofoam Foam Cutter, 100-240V/15W Foam Cutting Tool, 4" Hot Wire Foam Cutter (400℉) Suitable for All Kinds of Foaming Materials 3.1 out of 5 stars 84 $15.99 $ 15 . (~610mm x ~1825 mm x ~8mm) roll is $8. Whether your needs include having us create custom tool foam using a waterjet, having foam custom cut by us is no problem. Reducing the laser pulse frequency can also be a useful knob to turn but it's more fussy and can result in perforated cuts. I guess I'm happy that I'm not quite as fragile as the snowflakes you've run across before! Foams are made by trapping pockets of gas within a material. MINT Machining uses computer controlled laser engraving, laser cutting and laser marking systems. Didn't mean to take focus from your impressive work, just offer those inspired by it a possible option for materials. It comes in sheets 2'x4', in Black or White, or a "sandwich" of both colors. We are a hhighly acclaimed name in manufacturing and supplying Tools Foam Program. Kaizen Foam separates between the layers creating a perfect fit for storing all your tools in drawers and on walls. Thanks for the thoughtful comment. They have 2 ft. x 2 ft. x 1/2 in. I hope this Instructable gives enough information to help you find equivalent materials in your part of the world. Also, so much of the interlocking feature was cut away that the pieces didn't hold together at all. The laser easily cuts through a variety of foam thicknesses allowing you to precisely cut inserts that fit your specific tools. Railroad Rail Lantern / Sign Stand Split With Axe. Great Instructable! Keep in mind that cutting foam on a laser cutter is a greater fire hazard and use caution. Without the right tools, making those cuts and shapes can be messy, time-consuming, and a real hassle. We can even provide custom containers and custom-manufactured tools. Laser Cut Foam Shadow Tool Organizers Cutting foam for organizing tools - often called "tool shadowing" - is fast becoming a very popular laser application. to start laying out the foam … on Step 3. Even for larger quantities laser cutting now constitutes a real alternative to conventional processing methods such as die and knife cutters (cutting plotters). 6 years ago You're stuff looks amazing and I'm sure it will inspire people, so I wanted to let them know about a possible option for materials. Organizer Kits with Tools. Historically, it's been the haze that ends up on your inner surface of your car windshield after it's cooked out of the PVC dashboard. I'm not sure what I'll do when my present version of Illustrator, Photoshop, etc get too crunchy to continue to use. You may already know what I'm about to describe about laser optics, so sorry if this is redundant. 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