Aerospace & Aviation Tool Control Solutions
Supporting Safer, More Efficient Aircraft Maintenance
In the aerospace and aviation industry, safety, accuracy, and efficiency are non-negotiable. Foreign Object Debris (FOD) and misplaced tools can lead to serious safety risks, costly delays, and grounded aircraft.
OSAAP Australia has partnered with some of the country’s largest airlines and aerospace organisations, including Virgin Australia, Qantas, and Boeing Australia, to deliver effective tool control solutions.
We support airlines, MROs, manufacturers, defence contractors, and affiliated service providers with custom foam shadow boards, backer boards, precision laser etching, and Pelican cases — designed specifically to meet the rigorous demands of aviation environments.
Our digitally driven process and durable foam technology help aerospace teams maintain full control of their tools, reduce risks, and improve operational efficiency.
The Real Risks of Tool Loss and FOD in Aviation
Foreign Object Debris and Tool Accountability
One of the most significant challenges in aerospace and aviation maintenance is FOD. Lost or misplaced tools, loose hardware, and packaging materials are among the most common causes of FOD during aircraft servicing. When these items are left behind, they can compromise engines, control surfaces, and tyres, increasing the risk of damage, delays, and accidents.
Beyond safety concerns, FOD events lead to higher costs through equipment replacement, extended maintenance timeframes, and lost revenue caused by aircraft downtime.
The Cost of Searching for Missing Tools
Time spent searching for tools has a direct financial impact. According to the US Navy Safety Center, a single lost tool can cost between $10,000 and $250,000, factoring in search time, aircraft downtime, labour costs, and operational disruption. Grounded aircraft affect not only maintenance schedules but also crew availability, airport logistics, and flight operations.
Safety and Operational Consequences
Missing or misplaced tools can result in serious mechanical issues such as engine failure, reduced aircraft performance, or tyre damage. These failures can lead to accidents that endanger passengers, flight crews, and maintenance personnel, as well as significant financial losses associated with repairs and investigations.
Limitations of Traditional Foam Solutions
Many traditional foam products are not suited to the harsh conditions of aerospace environments. Standard foam can tear, stain, or degrade over time, offering insufficient protection for specialised tools.
More critically, traditional foam is not Skydrol® resistant, posing a major issue in aviation where Skydrol® is essential for hydraulic systems, brakes, and landing gear. Foam degradation can result in tool damage, contamination, and increased replacement costs.
How OSAAP Australia Helps Aerospace and Aviation Teams
OSAAP Australia combines durable, aviation-approved materials, custom foam shadow boards and backer boards, precision laser etching, and a fully digital workflow to help aerospace organisations improve safety, reduce costs, and increase efficiency.
As Platinum Pelican Dealers, we also advise on and supply Pelican cases to suit operational, storage, and transport requirements, ensuring tools are protected both in the hangar and in transit.
Our fast imaging process, remote project management, and deep understanding of aerospace environments make OSAAP a trusted partner for aviation tool control solutions across Australia.
Reducing FOD Through Shadow Boards and Laser Tool Etching
The effectiveness of shadow boards as a practical approach to tool control is widely recognised across manufacturing and maintenance industries. Studies referenced by the Lean Enterprise Institute show that reducing setup and search time can cut task completion times by up to 30%.
With clearly organised tools and immediate accountability, aerospace teams can work faster, more accurately, and with greater confidence.
OSAAP custom foam shadow boards, combined with precision laser tool etching, provide a clearly defined location for every tool within a tool kit, ensuring immediate visual confirmation that all equipment is accounted for. When a tool is missing, it is instantly identifiable, significantly reducing the risk of FOD.
Through improved tool visibility and accountability, OSAAP’s solutions can reduce tool loss by up to 25%, delivering measurable safety and cost benefits in aerospace and aviation environments.
Durable, Aviation-Approved Foam
OSAAP Australia uses high-performance foam manufactured by Zotefoams, engineered specifically for demanding aerospace and aviation applications. This foam is resistant to aggressive chemicals and solvents, including Skydrol®, and offers excellent flammability resistance. It is approved for use in aviation and space applications, making it suitable for hangars, MRO facilities, and flight-line operations.
Thanks to the inherent strength and durability of Zotefoams material, OSAAP custom foam shadow boards and backer boards are designed to withstand thousands of uses, delivering long-term reliability, reduced replacement costs, and consistent performance in hard-wearing environments.
Pelican Cases for Aerospace Tool Protection and Transport
As Platinum Pelican Dealers, OSAAP Australia supplies Pelican cases which can be fitted with our custom foam boards which are designed specifically for aerospace tools and equipment. The rigid, impact-resistant Pelican cases protect equipment during storage and transport, while the custom foam inserts inside the cases securely hold each tool in place.
This combination reduces the risk of damage, loss, and Foreign Object Debris (FOD), ensuring tools remain organised, protected, and fully accounted for in hangars, MRO facilities, and airside environments.
Scan Tools Without Disrupting Operations
OSAAP’s imaging technology and Blue Suite software make managing large or heavy automotive tools simple and efficient. Using the BlueMobile AUS app, technicians can capture tool images on site, removing the need to ship equipment offsite — an essential advantage for busy workshops and mobile service vehicles.
These images are then used by the OSAAP design team to create fully custom foam shadow boards and backer boards, with dimensions and thickness tailored to support even the heaviest tools. Precision laser etching can be applied to ensure every tool has a clearly defined, permanent location. For larger or high-volume tool sets, light panels and towers allow multiple items to be captured at once, improving speed, consistency, and accuracy.
All designs, approvals, laser etching specifications, and production progress are tracked through Blue Manager within Blue Suite, providing complete visibility, fast turnaround, and minimal disruption to operations.
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Discover how OSAAP Australia can engineer a smarter, safer, more efficient workspace.