I have a modest little collection of pocket knives and have been keeping them in a wooden box. It was cramped, they often scratched against each other and it was hard to get them in and out. A while ago I purchased a Pelican-style case from Oakley (another one of my obsessions) and decided that that case would make a much better knife box, if only it had custom foam…hmm…
You obviously you know what is going to happen here. A little measuring, some cheapie EVA foam from Harbor Freight floor tiles and viola!
First I laid out the knifes on my scanner so that I could use that as an outline for the shapes.
Then I brought that into Illustrator and used the pen tool to draw outlines for each knife. In retrospect I’d make the outlines even closer, but this works well for this particular case.
Then I cut out the foam, using 5 solid layers of just the outer line (the case was about 2.5" deep and each sheet was a little under half an inch thick). Then I cut out the top layer with the holes for the knives. I used a speed of 200 and power of 85 and got a clean cut.
Put all the layers into the box, place the knives and we are done! The foam in the lid keeps everything snug. I probably could cut another layer with all the holes so all the knives sit deeper in, but this setup makes it much easier to get them out.
Nice! The only little oddity while doing this project was that I would hit print and once it processed the GUI window would come up with a time of 49 seconds. The button glowed on the forge, I would press it, the fans would turn on, and then it would sit for a solid 10 seconds. Then it would move and start the cut and the GUI would immediately jump to 35 seconds. The timer would hit 0 in the GUI but then it still kept cutting for a few more seconds. Just generally seemed like the timing was off for the entire operation. Haven’t seen that before, and my test cuts in the foam with a little square worked normally and started movement/cut immediately, so I have to assume it was something in the file