Custom foam design, as simple as ordering a pizza
Designs that took hours of skilled CAD work now take under a minute
An AI-powered tool that turns a photo or a sketch into a custom foam insert in under a minute. I orchestrated the team and shipped it solo, end to end.
The problem
Custom foam inserts, the kind that hold tools or gear inside a case, are a pain to design. The existing tools are old and unforgiving. You need real skill to produce a 3D model a CNC machine will accept, and then hours of careful work to make it production ready. Condition1 wanted the opposite of that: a tool so simple that ordering a custom foam design would feel like ordering a pizza.
What I built
I came in as a consultant and architect and ended up carrying the whole thing to the finish. There was a product owner with the idea, a product designer, and an AI/ML engineer, and I was the one connecting all of it. I turned the idea into a technical flow, shaped the user journey with the designer, built the AI agents with the ML engineer, and took it from concept to shipped.
The work went deep on every layer. I built a 2D drawing tool so users could sketch directly, a 3D canvas to preview the result, and AI agents that could read a photo from someone's phone and turn it into precise measurements. From the Three.js model I generated the actual DXF files a CNC machine can cut. The part I did not expect to spend so long on was the human one. I spent hours talking and emailing with the CNC engineer to learn how they work and which files they trust. I sat nine thousand miles away, sending cuts, waiting for feedback, adjusting the algorithm, and sending the next one until it came out right.
The result
For most orders, generating a custom foam design now takes less than a minute. What used to demand a skilled hand and hours of CAD is now a few simple steps, and the cut file lands on the CNC engineer's desk ready to go. I delivered the first version end to end, and a second one with more features is next.