CNC Foam Cutting Service

What Makes Our CNC Foam Cutting Special

At Istar Machining, we use cutting-edge technology to shape foam materials into exactly what you need. From simple to complex shapes, our machines can do it all with amazing precision (as little as 0.1mm off). This makes us perfect for making:

• Custom packaging inserts
• Airplane insulation
• Car padding and seats
• Architectural models
• Display signs and art
• Furniture padding

We work with many types of foam including polyurethane (PU), EPS (the white foam in packaging), EVA (the soft foam in sports equipment), and phenolic foam (fire-resistant foam).

How Our CNC Foam Cutting Works

Our machines use either multi-wire cutting or telescoping blades to cut foam with amazing detail. Here’s what makes our process special:

Our foam CNC milling experts can take your design from idea to finished product with ease. We help you pick the right foam for your project and cut it perfectly.

Industries We Serve

Automotive

Our foam cutting creates perfect car seat padding and firewall insulation. Using our automotive CNC machining expertise, we make parts that fit perfectly in vehicles.

Aerospace

The aerospace industry needs lightweight, precise foam components. Our precision CNC machining delivers foam parts that meet strict aviation standards.

Packaging

We create custom foam inserts that keep fragile items safe during shipping. Our nesting optimization means your packaging is both protective and cost-effective.

Construction

Our insulation boards and acoustic panels help buildings stay warm and quiet. We can cut complex shapes for special building designs.

Materials We Work With

Our CNC routing foam service works with many foam types:

• EPS Foam – Light, cheap, great for packaging and models
• EVA Foam – Soft, flexible, perfect for padding and sports equipment
• Polyurethane Foam – Versatile foam for many uses
• Phenolic Foam – Fire-resistant for safety applications
• XPS Foam – Dense, water-resistant foam for displays and signs

We can even work with special foams that have flame-retardant treatments for safety.

Advantages of Our CNC Foam Cutting

Save Money

• No tooling costs – We don’t need expensive dies or molds
• Less waste – Our nesting software uses up to 90% of material
• Fast setup – We can start cutting in under 1 hour

Save Time

• Same-day quotes – Upload your design and get pricing fast
• Quick production – Most orders ship in days, not weeks
• Flash cutting technology – Cuts foam faster than regular methods

Get Perfect Results

• ISO 9001-certified – Our quality is guaranteed
• Cycle knife systems – Give you clean, crisp edges
• CO2 laser cutting – Perfect for detailed logos and designs

Technical Details

Our machines include 5-axis CNC routers with vacuum tables that hold foam perfectly still while cutting. We can work with foam from 5mm to 1,000mm thick.

For special needs, we offer:

• Edge sanding for smooth finishes
• Flame-retardant treatments
• Material nesting for better value
• Die-less die cutting for complex shapes
• Kerf compensation for perfect fit

This is all part of our rapid CNC machining service that gets your parts done fast and right.

Real-World Applications

Theater Props and Sets

We create lightweight, detailed foam props for theaters and movie sets using our Flash Cutting Technology. These props look real but weigh much less than the real thing.

Medical Equipment

Our ISO 9001-certified processes make sterile foam components for medical devices and surgical trays. The precision of our cuts (±0.1mm) ensures perfect fit for sensitive equipment.

Retail Displays

Our Cycle Knife Systems create eye-catching foam letters and displays for stores. These displays are lightweight but durable enough for public spaces.

Custom Furniture

Using our 6-Axis CNC Mobility, we create ergonomic chair backs and cushions that provide perfect support. The complex curves are no problem for our advanced machines.

How To Order

Getting started with Istar Machining’s CNC foam cutting service is easy:

1. Send us your design file (we accept CAD formats)
2. We’ll review it and provide a same-day quote
3. Once approved, we start production
4. Your custom foam parts are shipped to you

Need design help? Our engineers can help optimize your files for the best results and lowest costs. We also offer prototype CNC milling for test pieces before large orders.

Why Choose Istar Machining

When you work with Istar Machining for your foam cutting needs, you get:

• Expert knowledge in technical foams
• Advanced machines with telescoping blade mechanics
• Flash Cutting technology for faster production
• Nesting capabilities that save you money
• No tooling costs unlike traditional die cutting

Our CNC foam carving service can create anything from simple packaging to complex 3D art installations.