OSAAP: Start to Finish

We’re a custom-fit, full-solution process. And we go beyond all requirements to make the custom tool inserts that will work for you. For every project, every time. No matter what equipment you have, expect the highest quality–and not to mention, fastest–shadow boards through our proven and precise process. But that doesn’t mean we’re not collaborative. Within our customer interface, every client can be involved in as many steps of the process as they choose–from taking perfect photos of their tools, to the design process in our easy-to-use custom CAD software. From day one of production, your project is under control. And we mean precision-control. We generate instant and unique NC codes to create a shadow board of any size with any tool combination. Best of all, we rely on state-of-the-art manufacturing processes paired with our proprietary software to create the perfect space for each individual tool.

Step 1: Image

We can import your CAD files, 1:1 tracing, 2D images taken on our light panel system, or 3D images developed using the Obi3 Scanning system. See the process detail pages for in-depth information on each process.

Step 2: Design

We offer free design services to all of our customers. If you want to create your own design in our custom CAD software, we offer multiple solutions to aid you in learning how to use it. To schedule a meeting with our design department, you can visit our bookings page. We offer several different options for meetings so that our tech support agents can easily guide you through the shadow board creation process. In addition, we offer a multitude of support articles to guide you in your process. Blue Shadow is a very user-friendly CAD software that we have developed specifically to design shadowboards and inlays for cases. You can download Blue Shadow for FREE and get started designing your board.

Step 2.1: Blue Shadow

Once the models for all your parts have been created, we design each layer of the foam to hold your parts in our proprietary CAD Software, “Blue Shadow”. Blue Shadow is a FREE download available to our customers at no charge. It is a simple CAD software designed specifically for laying out parts in foam and can be used with minimal training.

Blue Shadow imports .jpeg files of images taken on our light panel. The frame of the light panel is used as a known datum, allowing the software to scale everything inside the frame from the known dimensions. Once scanned in, the CAD features allow for quick and easy design and layout of a Shadow Board.

Blue Shadow is based on a linear flow concept. Simply define the size, color, and thickness of the shadowboard needed, import the .jpg of your tools, and begin your design. Customize your board with easy-to-follow icons to straighten and align your tools. Slots for finger access can be added with two clicks of your mouse. Text can be customized and placed on your board with a range of fonts and sizes. Final check will highlight errors in red. Tool files can be individually saved to allow you to build a database. When you are done, save the shadowboard file in our proprietary .bord format and email it to us.

Step 3: Web Portal

Obtain a new project web portal from OSAAP. The portal contains all the information for your project, with each board collated for individual management. Once your images are uploaded to a project portal, we will start your design for FREE. With the combination of our Blue Shadow software and our design support, you can interface with your projects at the level that fits your schedule without delaying the workflow.

All files (help files, .tool files, .bord files, scan files, etc.) related to a project or design are uploaded to the web portal for one of our design teams and customers to view at the same time. The customer has the power and ability to either download our Blue Shadow FREE CAD software, or enlist a designer to create their custom board design.

The customer can send help tickets, live chat, and manage their board designs through this application. The customer is also able to review the design, and they have the power to approve their board designs and send into the manufacturing queue, or deny their board and ask for changes as many times as they need.

We pride ourselves on creating a user-friendly process.

Step 3.1: Project Management

We have found that project management is central to our success in managing low volume or high mix projects. As a result, our R&D budget has been focused heavily on our project database called “Blue Manager”.

Blue Manager has an internal-facing and customer-facing interface. All the work done on your project is transparent on the customer portal.

Features and Functionality:
1. If you upload your own design, you can track the progress of your project through approval and manufacturing.
2. If you upload CAD data, tracings, or images, your project starts the free design loop immediately.

Step 4: Edits & Approval

Whether you upload a completed design or only images and we design for you, we send an email notification after our review is completed. Upon login you will find an approval pdf, help photos, your completed design and all your revision history for traceability.