Use Kaizen foam inserts for custom-fit drawer and case organization

Line tool drawers, tool boxes, or cases with layered Kaizen foam, then cut out custom-shaped cavities for each tool. Every tool gets a precisely shaped pocket, tools stay put during transport, and a missing tool is immediately obvious from the empty cavity.

How It Works

Kaizen foam consists of thin pre-scored or layered sheets of closed-cell foam (typically 1/2-inch layers that peel apart). You trace the outline of each tool on the top layer, cut out the shape with a sharp knife, and peel away the foam layers to the depth needed. The result is a custom-molded insert that holds each tool snugly in its own pocket.

Step-by-Step

1. Measure the inside dimensions of your drawer or case
2. Cut Kaizen foam sheets to fit the drawer
3. Arrange your tools on top of the foam in the desired layout, leaving 1/2 inch between tools
4. Trace each tool outline with a fine-point marker
5. Cut along the outlines using a sharp utility knife, X-Acto knife, or hot wire cutter
6. Peel away foam layers to the depth of each tool (most Kaizen foam has pre-scored layers for this)
7. Test-fit each tool and trim as needed for a snug but easy-to-remove fit
8. Place the completed insert in the drawer

Tips

• FastCap is the original and most popular brand of Kaizen foam; available in black, white, red, and other colors
• A contrasting color foam (e.g., red base with black top) makes missing tools stand out dramatically
• Use a new, sharp blade for clean cuts; dull blades tear the foam
• For power tool cases, this method provides far better protection than the factory molded inserts
• Hot wire foam cutters give the cleanest results for curved shapes
• This technique is used in professional aviation, medical, and military applications for critical tool accountability

Common Mistakes

• Cutting cavities too tight: tools should slide in and out easily, not require force
• Not leaving enough foam border between tools: thin walls between cavities tear easily
• Cutting all the way through to the bottom: leave at least one foam layer as a base