Foam insert designer

Spark Fabrication v67 · 19 Oct 2026

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Start from a stock size Width mm Length mm Thickness Corner radius Foam

Sheets

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One project can hold several sheets (one per drawer or tray): the tabs above the foam switch between them. Each sheet is quoted, printed and downloaded on its own. Select tools and move them to another sheet with the row above.

Trace a photo

1Source

Print a tracing sheetLetter A4 A3 Tabloid

Shiny or chrome tools: print the dotted sheet instead: Letter · A4 · A3 · Tabloid. On matte green paper (black dots): Letter · A4. The designer reads the dots and the paper colour by itself.

Print at 100 % (never "fit to page") and check the 100 mm bar with a ruler. Lay the tools on the sheet with a finger's width between them and photograph the whole sheet from straight above. Long tools: butt two or three sheets edge to edge. Pick the same paper under "Paper in the photo" after the upload.

Photo or video

Import photo, video or DXFor drop a file on the sheet

Photo: shot from straight above, the original file (a WhatsApp copy loses detail); camera raw files work. Video: move the phone slowly across the sheet and back (5–10 s, 50–70 cm up, all four corner marks in view), the sharpest frames are stacked so a tall tool's sides and your shadow fall away. DXF: laid over the sheet as a guide; its closed shapes can become pockets.

2Paper & scale

Paper in the photo

Auto-scale: the sheet's corner marks set the scale and straighten the photo; pick the paper you printed on above. With several sheets butted together the designer works out the layout from the marks. Drag the photo to move it and its corner handle to resize it. Paper colour: white is best for dark tools; chrome and silver tools mirror the paper, so print the sheet on light blue or light green matte paper for those. Even daylight or two lamps from the sides, no flash, no patterned mat under the sheet.

3Image adjustment

Auto brightness: lift the paper to white Brightness 0 Contrast 0 Detail Contrast boost

Contrast boost stretches the photo and sharpens local contrast before the detector looks at it, and lets the AI's find grow into high-contrast parts it missed (a chrome head). Specks are dropped automatically. Smoothing irons out ripples and uses fewer points. Close gaps fills jaws, slots and openings narrower than the setting so the pocket stays one solid shape. Tool height corrects for the camera seeing the top of a tall tool wider than its base. That correction only runs with a trusted camera height: from the photo's lens data (upload the original file), from the zoom you pick, or typed under Camera height; otherwise the trace is the full silhouette and nothing shrinks. Hover any Advanced setting for what it does.

4Detection

Method Sensitivity Clearance 1.0 mm Smoothing 1.0 mm Close gaps up to 0 mm Shadow removal 35 % Read the dots of a dotted sheet Snap to the edges in the full photo Keep touching tools apart Correct for tool height (camera height needed) Tool height mm Tool shape Zoom used Camera height cm

5Trace

Keep the photo until I complete the trace

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