Achieve precision and customisation with CAD design services at Kewell Converters

Explore how Kewell Converters uses advanced CAD technology to design high-precision, custom foam solutions for any industry

When it comes to precision engineering and bespoke foam solution production, Kewell Converters leads the way with its expert CAD design services. From concept to creation, our skilled engineers are dedicated to ensuring each foam conversion project meets the highest standards of quality and functionality.

This blog will explore what CAD design entails, how Kewell Converters excels in its application, and why our expertise sets your projects apart.

What is CAD design and how does it work?

Computer-Aided Design (CAD) is a powerful process that uses specialised software to create digital models of real-world objects with exceptional precision. It’s the perfect bridge between your initial idea and the final product, enabling our engineers to visualise, test, and refine designs digitally before any physical production takes place.

With CAD, engineers can:

• Visualise concepts in both 2D and 3D for an enhanced understanding of the design
• Refine and simulate designs to anticipate how the product will behave in the real world
• Ensure accuracy and feasibility to eliminate costly errors in production

The power of CAD lies in its ability to transform even rough sketches or abstract ideas into detailed, manufacturable designs. By leveraging this technology, we eliminate guesswork, reduce errors, and ensure that every design is optimised for production efficiency and final functionality.

How long does the CAD design process take?

The CAD design process can vary significantly depending on the complexity of the project. Simple foam inserts may only require a few hours of design work, while more intricate foam components may take over a week, involving extensive research and testing. Our approach ensures that every project, regardless of size or complexity, receives the attention and time it needs to achieve the best possible result.

How Kewell Converters uses CAD

At Kewell Converters, CAD isn’t just a tool; it’s the core of how we bring your vision to life. Our highly skilled CAD/CAM engineers like Joel are experts in working with foam and its unique properties. We treat every project as a custom challenge, offering solutions that are not only functional but also optimised for performance.

From concept to creation

Whether you start with a fully developed idea or simply a rough sketch, our experienced engineers have the expertise to transform your vision into a precise foam design. Foam is a highly versatile material known for its lightweight and adaptable properties—but its irregularity and sensitivity to stress mean it requires expert handling. Our team’s deep understanding of foam ensures that every design accounts for its unique tolerances, ensuring the finished product performs as expected.

Foam conversion is a meticulous process that requires careful attention to detail, and our engineers have mastered the nuances of working with foam over the decades.  Kewell Converters draws on 50 years of specialised knowledge to perfect every aspect of the design, from material choice to structural integrity.

Cutting-edge tools and technology

To ensure the highest quality results, we use SpaceClaim CAD modelling software, which allows us to create:

• 2D visualisations that highlight the essential details of your product, making it easy to understand the design specifications at a glance.
• 3D interactive models that provide an immersive experience, enabling you to visualise and manipulate the design in a virtual environment. This hands-on approach empowers you to fine-tune and perfect your concept before it moves to production.

The use of these advanced tools ensures that our designs are not only precise but also flexible, allowing you to explore all possibilities before committing to the final design. This process gives you full control and confidence in the end result, offering clarity and understanding of how your product will take shape.

And we’re embracing AI to streamline drawing and CNC programming, enabling faster, smarter design iterations. AI-driven tools help us optimise material usage, improve cutting paths, and reduce production time—delivering even greater precision and customisation in every foam solution.

By integrating these intelligent technologies, we continue to push the boundaries of what’s possible in foam engineering, keeping your projects at the forefront of innovation.

Why choose Kewell Converters?

Kewell Converters has built a reputation as one of the UK’s leading foam converters and CAD design foam specialists. We combine decades of experience with cutting-edge technology to deliver exceptional results for every project. Here’s why Kewell Converters stands out:

• Expertise in foam conversion: We’ve specialised in foam for over 50 years, making us the experts when it comes to working with foam materials. Our deep understanding of foam’s properties allows us to create precise, custom solutions that our competitors simply cannot match.
• Attention to detail: From the initial 2D sketches to interactive 3D models, we leave no stone unturned in making sure every aspect of your project is perfectly executed. Our designs are more than just drawings—they’re detailed blueprints for success.
• Innovative technology: With advanced CAD tools like SpaceClaim and our experienced team, we ensure that each project is completed with the highest level of precision. These tools allow us to optimise every design, ensuring efficiency and accuracy from concept to production.
• Collaborative approach: We believe in working closely with our customers, keeping you involved at every stage of the process. Whether it’s feedback on initial designs or fine-tuning the final product, we’re committed to creating solutions that match your specific requirements.
• Commitment to quality: Our dedication to engineering excellence extends beyond the design phase. We take great pride in delivering foam products that not only meet but exceed your expectations. Every product we deliver is a result of our relentless pursuit of quality.

Bring your ideas to life with Kewell Converters

Transforming ideas into tangible solutions is what we do best. With our CAD design services and expertise in foam conversion, Kewell Converters ensures your projects are executed to the highest standard.

If you’re ready to elevate your business with bespoke foam solutions, we’re here to guide you every step of the way. Our engineers are excited to collaborate with you to create designs that are as practical as they are precise.

Get in touch with Kewell Converters today to discuss your needs and discover how our CAD design services can make your vision a reality.