How accurate is smartphone A4 / US Letter paper homography tool tracing?

FoamKerf solves an exact 8-DOF 3x3 projective homography matrix from the 4 corners of an ISO A4 (297.0x210.0mm) or US Letter (279.4x215.9mm) sheet, removing camera tilt to achieve +-0.2mm orthographic contour precision.

What minimum wall thickness should I keep between Kaizen or EVA foam pockets?

Maintain at least 8.0 mm (0.315 in) of closed-cell polyethylene or EVA38/EVA45 foam between adjacent tool cutouts and case walls to prevent foam ribs from tearing.

Which machines accept FoamKerf DXF, SVG, G-code, and STL files?

AutoCAD R12 1:1 millimeter DXF and color-layered SVG open directly in LightBurn, xTool, Glowforge, and Epilog CO2/diode lasers; .nc G-code runs on GRBL 3-axis CNC routers; watertight binary .STL prints directly in Bambu Studio, PrusaSlicer, and OrcaSlicer.

Apache Hard Case · 1:1 CAD Ready

Harbor Freight Apache 3800 Custom Foam Insert Template

Replace pick-and-pluck cubes in your 378×268mm (R16) Apache 3800 hard case with precision laser-cut closed-cell EVA foam.

Case Interior

502×279mm

Min Foam Rib

22.8 mm

1:1 Cut Path

3.96 m

5S CAD Audit

98/100

1. Case Model, Foam Fit & Pocket Inspector100% Client-Side CAD

Quick Multi-Tool Kit Preset

Target Hard Case / Tool Chest Drawer (28 Models)

Radial Fit Offset (mm)

Laser Melt Kerf (mm)

5S Base Reveal Foam Color (Under Charcoal Top)

2. Selected Tool Pocket Inspector

Tool Name

Cut Depth (mm)

18mm Finger Pull

Active Tool Pockets (Click or Drag on Canvas)

Case Interior L×W

502 × 279 mm

Max Depth 147 mm

Narrowest Foam Rib

22.8 mm

PASS >= 8.0mm Rule

Total 1:1 Cut Path

3.96 m path

~4.2 min CO2 Laser

CNC / 3DP Estimate

6 Pockets

~18.4 min CNC Router

Automated 5S Foam Rib Collision, Z-Depth & Laser Kerf Linter 98 / 100 READY

45-Second Live Studio Walkthrough

Smartphone Photo on A4 / Letter Paper → 1:1 Laser DXF, GRBL CNC G-Code & Rigid Packout STL

Eliminate manual caliper tracing, Adobe Illustrator scaling headaches, and $140+ custom foam markups. FoamKerf Precision Studio computes 8-DOF projective homography, Marching-Squares silhouette contours, kerf offsets, and 18mm finger notches 100% locally in your browser.

28 Verified Case & Drawer Profiles: Pelican 1510, 1535 Air, 1450, 1615, Vault V700, Milwaukee Packout, Apache 3800/4800, US General & Snap-on KRL.
8-DOF Projective Homography (±0.2mm): Rectifies tilted camera photos on ISO A4 (297×210mm) or US Letter (279.4×215.9mm) paper instantly.
4 Production CAM Formats: AutoCAD R12 1:1 .DXF, LightBurn .SVG, 3-Axis GRBL .nc G-code & Watertight Binary .STL ($12.90 Single Cut Pack).

CAD Fabrication & Fit Guide: Harbor Freight Apache 3800 Custom Foam Insert Template

Replace pick-and-pluck cubes in your 378×268mm (R16) Apache 3800 hard case with precision laser-cut closed-cell EVA foam. Pre-calibrated preset: target enclosure apache_3800, kit layout electronics_1450, radial fit clearance +1.0 mm, laser melt kerf +0.2 mm, and 18mm semicircular finger-pull notches.

Related Case, Packout & 5S Foam CAD Tools

Pelican 1510 Foam Insert 1:1 Laser DXF Generator — Generate exact 502×279mm (R18) Pelican 1510 carry-on foam insert DXF, SVG, and CNC pocket G-code with 18mm finger notches.
Pelican 1535 Air Camera & Drone Foam Layout CAD — Design custom 518×284mm (R18) Pelican 1535 Air camera, cine lens, and drone battery foam trays with 8mm minimum rib collision checks.
Milwaukee Packout Custom Foam DXF & 3D-Print Insert STL — Export 1:1 laser-cut Kaizen foam DXF or watertight 3D-printable rigid drawer insert STL files for Milwaukee Packout organizers.
Kaizen Foam Smartphone Photo-Trace to 1:1 DXF Studio — Snap any tilted smartphone photo of tools on an A4 or US Letter sheet and rectify to ±0.2mm 1:1 Kaizen foam cut vectors.
5S Two-Tone Tool Shadow Board Laser DXF & Etch Planner — Build high-contrast two-tone 5S Lean tool control shadow boards with automated 18mm semicircular finger pulls and laser etch labels.
GRBL 3-Axis CNC Router EVA Foam Pocket G-Code Generator — Compile multi-depth Z-stepdown raster pocket clearing G-code (.nc) for 6.35mm (1/4 in) downcut EVA and polyethylene foam endmills.
DeWalt ToughSystem 2.0 Custom Foam & Rigid Insert CAD — Precision 475×305mm (R14) DeWalt ToughSystem 2.0 foam insert and 3D-printed tool tray generator with live rib thickness audit.
US General Series 3 Tool Chest Drawer Shadow Foam CAD — Lay out wrenches, pliers, micrometers, and sockets for Harbor Freight US General Series 3 roll cab drawers in 1:1 millimeter scale.

Verified Hard Case & 5S Drawer Internal Dimensions, Corner Radii & Foam Depth Matrix

Exact internal millimeter clearances used by FoamKerf Precision Studio for 1:1 AutoCAD R12 DXF, CNC router G-code, and 3D-printable rigid STL inserts:

Case / Drawer Model	Internal L × W (mm)	Max Foam Depth	Corner Radius	Recommended Foam / Insert Spec
Pelican 1510 Carry-On	502 × 279 mm	147 mm	R18 mm	50mm + 50mm EVA38 + 25mm Convoluted Lid
Pelican 1535 Air Carry-On	518 × 284 mm	183 mm	R18 mm	Two-Tone Kaizen 57mm + 57mm Base Stack
Pelican 1450 Protector	372 × 260 mm	154 mm	R16 mm	Closed-Cell XLPE / EVA45 Precision Cut
Pelican 1615 Air Check-In	752 × 394 mm	238 mm	R22 mm	Multi-Layer Expedition EVA45 Stack
Milwaukee Packout 48-22-8435	386 × 248 mm	96 mm	R14 mm	57mm Kaizen or Rigid PETG 3D-Printed Insert
Milwaukee Packout 48-22-8430	457 × 356 mm	96 mm	R16 mm	Two-Tone Red/Black EVA38 or Binary STL
Harbor Freight Apache 3800	378 × 268 mm	152 mm	R16 mm	Laser-Cut EVA Replacement for Pick-Pluck
US General Series 3 Top Drawer	612 × 495 mm	72 mm	R4 mm	20mm–30mm Two-Tone 5S Lean Shadow Board
Snap-on KRL722 Wide Drawer	889 × 598 mm	98 mm	R4 mm	AS9100 / FOD Two-Tone Aviation Control Foam