Possible solutions for custom inserts

[gaius]

Hi, I'd like to make custom tool inserts for Festool Systainers and Bosch L-Boxxes.

Initially my plan was to cut Kaizen foam on a CNC. Cork is harder than the foam, but still soft and light enough to achieve a good result, and would also be amenable to CNC shaping.
Do you have suggestions for other soft+light materials suited for this - perhaps like the denser foam used by Wera in their toolboxes (eg in their Zyklop ratchet sets -https://www.amazon.com/Wera-Zyklop-Metric-Ratchet-Piece/dp/B07VV6M8DN )?

After seeing a few posts here of people 3d printing their own inserts (box-like containers), I now wonder if this is the best solution.
Perhaps I could print thin plastic (negative) shapes, like those used by Festool for power tools. Does this seem feasible? If so, what filament would be best?

Yet another option would be to print a whole block to fit the systainer, with blanks on the surface shaped like the tools - ie the end result would be similar to CNC cutting a block of Kaizen foam, only with a different base material. To keep weight down, the structure would probably need to have a honeycomb-like structure? And printed in a softer material (TPU, other?)

I'll soon have access to a 3d printer and CNC machine, and don't want to waste time reinventing the wheel, so would appreciate your opinion/experience.

cheers

 

[Christopher Fitch]

I would try this foam:

EVA Foam Sheets for Kids Craft Cosplay Model 13.7"×39" Thickness 1-10mm (High Density 79 kg/m³)

I picked up some of that (10mm thick sheets) and it's perfect for inserts in my opinion. I have a number of inserts I plan on making - just need to do it.

 

[Peter_C]

By some 1/8" ABS, and some 3/16" ABS and go to town. ABS is awesome to work with. You can heat it and bend it. Super easy to glue with a solvent applied while set in place. The stuff is tough and works very similar to wood in that you cut and route it just at a slower speed. I just purchased a couple more sheets for making things. The solvent can be purchased from Amazon or places like Tap Plastics if you have one nearby.

 

[rst]

Foamorder.com has EVA foam in thickness' up to 4" thick in 40 x 80 sheets. 

 

[Packard]

You can use your CNC machine to make molds for Kydex plastic and then use the CNC to do the finish cuts on kydex.

Kydex is the material that the interior panels on passenger aircraft are made from.  They are "draped" heat-formed panels.  That means that the panels are placed over a "mold" and then heated to about 300 degrees, and the kydex sheets will follow the contours of the mold.

These are used regularly for the manufacture of holsters.  You can find articles on line that detail this using a toaster oven. 

Once you have the basic shape for the insert, you would use the CNC to mill any holes or slots that are required.  The advantages of kydex is that it is seamless and if the design becomes a large production number, you can have an outside vender mold this automatically at a greatly reduced cost (after paying for the tooling).

Also note that in the unformed condition it is barely 1/8" thick and will take up very little space in your shop.
https://www.google.com/search?client=firefox-b-1-d&q=forming+kydex+sheet