PRECISION SHADOW BOARDS. MEASURABLE RESULTS.

Built for Control.
Designed for ROI.

OSAAP solutions help engineering, maintenance, and manufacturing teams reduce waste, protect critical assets, and improve operational performance where it matters most.

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Reduce FOD

Make missing tools immediately visible and reduce the risk of foreign objects, downtime, damage, and rework.

Improve Accountability

Give every tool a defined location and create clear visual ownership across teams, workstations, and shifts.

Protect Your Investment

Precision-cut foam protects valuable tools from impact, movement, loss, and unnecessary wear.

Standardize Processes

Create repeatable tool layouts that improve consistency, training, quality control, and workflow efficiency.

Better Control. Better Performance. Better ROI.
A BETTER WAY TO BUILD SHADOW BOARDS

From Disconnected Steps to One Connected Workflow

Traditional shadow board projects rely on scattered files, repetitive handoffs, and manual revisions. OSAAP connects tool capture, design, approvals, and manufacturing within one traceable platform.

Traditional Workflow

A Disconnected Process

Project information moves between separate systems, people, and production stages.

01
Capture Project Information Photos, tool lists, dimensions, and reference files are gathered manually.
02
Send Files by Email Project information becomes distributed across multiple email chains and attachments.
03
Wait for Design A designer creates the layout using separate software and disconnected project files.
04
Review and Revise Changes require additional emails, updated attachments, and repeated manual communication.
05
Move to Manufacturing Approved design information must be transferred into a separate production workflow.
The Result Longer timelines, disconnected files, and limited traceability.
Recommended Approach
The OSAAP Workflow

One Connected Platform

Every stage stays connected—from tool capture and design to approval, production, and future updates.

01
Capture Your Tools Use an OSAAP light panel, Blue Mobile, CAD files, tracings, or existing images.
02
Create and Organize Your Project Manage toolboxes, drawers, boards, media, and supporting files through the Web Portal.
03
Design Collaboratively Create the board in Blue Shadow or use OSAAP’s free professional design service.
04
Review and Approve Online View approval drawings, submit revision notes, and maintain a complete project history.
05
Manufacture with Precision Approved files move into nesting, production preparation, and precision manufacturing.
The Result A faster, traceable workflow that remains accessible for future revisions, reorders, and expansion.
THE TECHNOLOGY BEHIND THE PROCESS

One Connected Software Suite

The Blue Software Suite connects every stage of the shadow board process—from capturing tools and creating layouts to managing revisions, nesting files, and preparing designs for production.

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Capture Design Manage Manufacture
01
Tool Capture

Blue Mobile

Capture scaled tool images, create new projects, and monitor active shadow board designs directly from a mobile device.

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02
CAD Design

Blue Shadow

Create precise shadow board layouts from scaled tool images using OSAAP’s purpose-built CAD software and native .bord file format.

Explore Blue Shadow
03
Customer Access

Web Portal

Organize files, help photos, approvals, project communication, and revisions in one centralized customer workspace.

Explore the Web Portal
04
Project Management

Blue Manager

Coordinate design activity, project history, customer communication, and production status through one traceable management system.

Explore Blue Manager
05
Production Preparation

BlueNest

Nest OSAAP .bord files and create drill orders that can be converted into NC Code or DXF files for approved production equipment.

Explore BlueNest
ONE SYSTEM. EVERY STAGE.

Built to Keep Every Project Connected

Each application supports a different part of the process, while keeping project information, design files, approvals, and production data connected from beginning to end.

View the Complete Suite
FROM CONCEPT TO COMPLETION

The OSAAP Shadow Board Process

See how OSAAP takes your project from tool image capture and collaborative design through approval, precision manufacturing, and final accessories.

01
Image Capture

Capture Your Tools

Arrange your tools on an OSAAP light panel or capture them using Blue Mobile. These images provide the scale and tool profiles needed to create an accurate shadow board design.

Tools arranged for OSAAP image capture
Built for future updates. Your project files and approved layouts remain organized, making it easier to reorder, revise, expand, or standardize your shadow boards.
Custom OSAAP precision foam insert for engineering test equipment
TRUSTED BY ENGINEERS

Built to Perform.
Built to Last.

“When the finished shadow boards arrived at the office our team was blown away! It is far superior to the previous die cut and laminated foam inserts that were being used previously and fail within months of normal use. The quality and precision of the foam is incomparable to anything we have seen before. The foam is robust and the color options are a great touch to match your company colors or for additional organization.”
Mike Letchworth High Voltage Battery Test Engineer
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Frequently Asked Questions

How long is the lead time for a shadow board?

Our design services typically require about 48 hours for initial completion. However, the timeline may vary depending on the extent of revisions needed. Once your board design is approved for manufacturing, our standard lead time for shipment is approximately 2 weeks.

Can You Convert CAD Files to .bord Files for use in OSAAP's Blue Shadow CAD Software?

Yes, we have two methods of converting CAD files

  1. For .STEP files we open the files in Solidworks, save it as a .STL and use our Slicer Software “OPath” to generate a .bord file for our milling process.
    1. Sending us an .STL avoids the conversion step
  2. For DXF files open the file in CorelDraw and convert it to a .bord file
    1. This is used for simple tool files not complex shares

Can OSAAP Foam Withstand Skydrol's Damaging Properties?

In short, the answer is yes, our foam can withstand the chemical properties of Skydrol. We currently have multiple customers that use our foam paired with Skydrol applications. Our foam is inert, blown-in Nitrogen, so it does not react except under very extreme conditions; the thermal limit of the foam is 500 degrees F. Skydrol leaves a thin film on the exterior of the foam. It does NOT dissolve the material.

 

Learn More

Can I use My Own Camera?

For optimal performance, we recommend using only the cameras supplied by OSAAP or your mobile phone with our dedicated blue mobile application.

What Files Types Can We Upload?

The best way to provide OSAAP with information and data about your board design is to upload them directly to the board in your project within your Web Portal Account.

You can upload images, excel files, pdf and more. You can also upload most CAD file formats.

 

A complete list of the file types you can upload follows below:

  1. Jpg: Image
  2. jpeg: Image
  3. csv: Table
  4. txt: Table
  5. tab: Tab;e
  6. ssv: Microsoft project plans
  7. xps: Microsoft's version of a PDF format
  8. oxps: Microsoft's version of a PDF format
  9. xls: Excel file
  10. xlsx: Excel file
  11. pdf: Adobe Systems extension is a Portable Document Format
  12. svg: A graphics file that uses a two-dimensional vector graphic format
  13. tool: OSAAP cutout shape on a board design
  14. bord: OSAAP board design
  15. dxfX: CAD format
  16. dwg: CAD format
  17. stl: CAD format
  18. stp: CAD format
  19. sldprt: CAD format
  20. igs: CAD format
  21. step: CAD format
  22. sat: CAD format
  23. x_t: CAD format
     

Is OSAAP ITAR certified?

OSAAP America maintains a separate server and web portal for data that is considered sensitive and should be restricted to US citizens only. While we are not on any government network or considered ITAR compliant, we ensure that our sub-contractors do not have any access to the server(s) or data that we have classified as “USA001”.

 

The USA001 web portal does have a warning message that clearly states that we are not ITAR compliant.
HAVE A QUESTION?

Let’s Talk About Your Project

Whether you are planning a custom shadow board, exploring the Blue Software Suite, or need help determining the right solution, our team is ready to help.

Contact Us
sales@osaapamerica.com (978) 450-0747