Concept Design

Whether you have a sketch or a 3D CAD model, we will assist in the design of your new foam product.


The reverse engineering of the pad involved taking dozens of measurements of the part geometry. Each of the unique sections of the part had to be measured and plotted on a two dimensional CAD drawing.

  • Plotting part geometry in CAD drawing
  • 2D drawing of half of part
  • Geometry mirrored to complete part design
  • 2D part geometry extruded to 3D solid model
  • Helmet pad drawing for customer review
Whether you have a conceptual sketch or a 3D CAD model, our team will assist in the design of your new foam product.
Click to scroll

This process was made much simpler as we use Solidworks™ for our CAD design. Fortunately, the pad was symmetrical from left to right, so we only had to plot and dimension one-half of the part. Our CAD software allowed one of our engineers to then mirror the part geometry of the opposite side of the part.Once the part geometry was designed

Once the part geometry was designed two-dimensionally, our CAD expert was able to use the extrude function of Solidworks™ to create the required depth of the part and then a 3D model. When the part design was finalized, we sent a dimensioned part drawing and a 3D CAD model of the part to our customer. They reviewed both and agreed that we had succeeded at the reverse engineering of the part geometry. We were asked to formally quote piece prices and the associated prototype and production tooling costs.