[ Replicade ]

Tool Control Foams

Getting Started

  1. Determine the tooling requirements for your project. Your Replicade rep can assist you in performing an initial tool audit. We are experienced with 5S or lean project reviews in cooperation with the manufacturing engineers, supervisors and line operators.
  2. Determine the storage space configuration which will work best for your application. This may be traditional tool boxes, shelving units, mobile cases, or work tables.
  3. Provide us with digital images of the items on our scanning grids. We can work with you to catalogue and digitally photograph all needed information at your location.
  4. Once all the images are digitised, we will provide you with layout drawings showing the finalised profiles and how the items will be arranged on the foams.
  5. The foam inserts are normally shipped two to three weeks after you have given us layout approval.
  6. A unique number is assigned to each foam insert layout to make re-ordering or future modifications very simple.

[ Foam Trays ]

Key Benefits

  • We use Plastazote┬« Foam which is closed cell polyethylene foam - it is lightweight, waterproof, oilproof, chemically inert, flexible and available in a large range of colours and densities!
  • The two-color foam permits immediate visual audits. If you can see the alert color - a tool is missing!
  • Our patented "push-down" system maximises the space available on a foam and makes it easy to remove a tool from the foam - push down on one end of the tool and the other end will pop up.
  • Three-dimensional routing matches the profile of the tool to accurately position and protect the tools in the foam.

[ Foam Trays ]

Tool Cases

We provide foam tool control for toolboxes of any size and shape

Organize your tools to meet your requirements!

  • Standard hand tools
  • Custom fabricated tools
  • Dies
  • Quality control gauges
  • Air tools
  • Machine set-up tools

We DO NOT need to remove tools from your facility to provide foam profiles. You approve all layouts prior to production.

Mobile Cases

Mobile cases large and small can be fitted with custom foam to organize, protect and identify your components in a glance.

We can provide the total package:

  • We can source the right case for your project
  • We can fit out the case with multiple layers of foam, each with a different set of tools
  • We can also source tools for you
Each kit can be customised with contrasting foam in your chosen colour!


The foam colour and density can be customised from a large range of options to suit your requirements. We can also add:

  • Handholds onto the foam edges - for easy access to multi-layer foams.
  • Fingerholds or push-downs - to make it easy to remove an item from the foam
  • Tally or barcode slots- for each item
  • Custom friction fit - we can customise the exact fit for each tool profile

[ Customisation Options ]