Custom foam shadow boards are precision-cut foam inserts designed to securely hold tools or instruments in place while providing a clear visual reference of missing items.

Backer boards provide a rigid mounting surface behind the shadow board or toolkit, improving durability and allowing for wall or case mounting. Together, they create organised, efficient storage that improves safety, reduces loss, and increases operational efficiency.

We primarily use foam from Zotefoams which specialises in a lightweight foam known for its durability and resilience. This foam features a closed-cell, waterproof structure that is oil- and chemical-resistant, heat resistant up to 105°C, and offers high tear strength and excellent compression resistance.

It is non-toxic, odourless, eco-friendly, and fully recyclable, making it ideal for high-precision shadow boards, backer boards, and inserts. The material absorbs shock, protects sensitive equipment, and maintains its shape over time, even in heavy-use industrial or defence environments.

Available in black, blue, red, or yellow, our foams can also be colour-coded to improve visibility, simplify organisation, or align with your brand or departmental requirements.

OSAAP Australia supplies high-quality, rugged transport and storage cases, specialising in Pelican Cases, which are ideal for protecting sensitive equipment. Each case can be customised with our foam Shadowboards, backer boards and laser etched labelling to suit your needs.

As a Pelican Platinum Dealer, OSAAP Australia provides access to a wide range of industry-leading protective transport cases.

Pelican cases are shockproof, watertight, and built to withstand demanding environments. They are fully customisable to fit our foam inserts and your equipment, making them ideal for defence, mining, medical, and industrial applications.

When combined with our custom foam, they create a complete, ready-to-use solution for protecting and organising critical tools.

Yes. Laser etching can be applied to our foam shadow boards, backer boards, or Pelican cases to provide permanent labels, part numbers, or branding. This ensures easy identification, reduces errors, and enhances traceability for inventory management.

While OSAAP Australia does not sell tools, we offer a comprehensive kitting service for clients who opt to send their equipment to us. We consult with you to recommend the most appropriate Pelican case or toolbox, design and manufacture the custom foam inserts, and assemble your tools into the cases professionally. The result is a fully organised kit that is ready to use immediately, saving time and ensuring consistent tool management.

Blue Suite is our proprietary digital workflow platform that integrates imaging, design, and project management. It allows clients to scan and upload equipment directly from site, review foam layouts and custom laser etching, approve designs digitally, and track progress from start to finish. By centralising the entire workflow, Blue Suite ensures accuracy, reduces errors, and allows tools to remain on-site instead of being shipped offsite unnecessarily.

The software suite is made up of three connected tools — BlueMobile AUS App, Blue Shadow, and Blue Manager — each designed to support a specific stage of the process while working together seamlessly.

The BlueMobile AUS App allows you to start your custom foam shadow board project directly from your phone. Using the app, you can photograph each tool on a blank sheet of white A4 sized paper to capture accurate scale and detail, then upload all project information in one place. You can review designs, request changes, and approve layouts digitally, all without removing tools from service. The app connects seamlessly to OSAAP’s design and manufacturing systems, ensuring a smooth, fully digital workflow from capture through to production.

Blue Shadow is OSAAP Australia’s dedicated CAD-based design software, used to create precision foam shadow boards. It converts scanned images of tools into accurate CAD files, ensuring every item has a defined, repeatable location. This precision improves accountability, reduces tool loss, and supports operational efficiency.

Blue Manager is the central project management platform that provides full visibility and control over your project. Through a secure web portal, you can upload requirements, review and approve designs, request changes, and track manufacturing progress, all in one place. It removes the need for emails or follow-ups and ensures your project runs smoothly from start to finish.

For larger or more complex equipment, we can provide light panels and cameras for clients to capture multiple items at once. The images captured using this setup are uploaded to the Blue Manager system, maintaining the same accuracy, efficiency, and seamless workflow as smaller projects. This ensures that even large-scale or complex tool collections can be managed digitally without compromising precision.

Yes. If you prefer, you can send your equipment to OSAAP Australia for professional scanning. Our team will capture precise images of each item to ensure accurate foam shadow board designs.

Yes. Every client has full access to review, request changes, and approve final designs digitally through our Blue Suite platform. This ensures that the final product meets every requirement and eliminates the risk of errors or misunderstandings.

We require a minimum gap of approximately 10mm separating each item in the foam. Click here to see exact measurements required. 

Yes. Our fully digital workflow allows us to provide solutions to clients anywhere in Australia, and we can ship completed foam shadow boards, cases, and kits directly to your location.

To start a project, simply contact us. We will consult with you to understand your tools, workflow, and operational needs before recommending a tailored solution that best suits your requirements.