CNC Foam Carving Service

Materials We Work With

We can carve many types of foam to meet your needs:

• EPS Foam (Expanded Polystyrene) – Lightweight white foam good for models and displays
• XPS Foam (Extruded Polystyrene) – Stronger than EPS, comes in colors, great for signs
• Polyurethane Foam – From soft to very firm, good for cushioning and props
• EVA Foam – Flexible and durable, perfect for costumes and padding
• High-Density Tooling Foam – For precise engineering models and prototypes

Our foam CNC machining experts will help you pick the right foam for your project.

How Our CNC Foam Carving Process Works

1. Design Phase – You send us your digital design files (STL, OBJ, CAD files) or we can help create them
2. Material Selection – We help you pick the best foam type and density
3. Machine Setup – Our technicians program the CNC machine with your design
4. Carving Process – The machine carefully cuts your design with special tools
5. Finishing – We can sand, seal, paint, or assemble as needed
6. Quality Check – Every piece is inspected to make sure it meets our standards
7. Delivery – Your finished foam parts are carefully packed and shipped

Industry Applications

Entertainment and Props

Our CNC foam carving service is perfect for making movie props, theme park elements, theater sets, and trade show displays. We can create large signs, character figures, and themed environments that look amazing but weigh very little.

Architecture and Design

Architects love our foam models because they show off building designs in 3D. We make detailed scale models of buildings, landscapes, and urban plans. These models help clients understand designs better than flat drawings.

Product Prototyping

Before making expensive metal or plastic parts, companies use our foam prototypes to test ideas. Our CNC routing foam service creates accurate test models for products, packaging, and parts at a fraction of the cost.

Packaging Solutions

We make custom foam inserts that protect valuable items during shipping. These foam pieces have exact cutouts that hold products firmly in place, preventing damage.

Aerospace and Engineering

The aerospace industry uses our high-density foam models for wind tunnel testing and concept models. Our precision CNC machining meets the tight tolerances these industries need.

Advantages of Istar Machining’s CNC Foam Carving

Precision and Consistency

Our machines can achieve tolerances as tight as ±0.005 inches. This means every piece we make will be almost exactly the same – perfect for projects that need matching parts.

Size Capabilities

We can work with foam blocks up to 10 feet long, 5 feet wide, and 2 feet thick. For even larger projects, we can carve separate pieces that fit together perfectly.

Complex Designs

Our 5-axis CNC machines can create complex curves, undercuts, and intricate details that would be impossible to make by hand. This opens up new design possibilities for your projects.

Fast Turnaround

Need your foam parts quickly? Our efficient process can deliver simple projects in 1-3 days and standard projects within a week.

Cost-Effective

Foam carving costs much less than working with wood, metal, or plastic. It’s perfect for prototypes, models, and one-time use items where budget matters.

Lightweight Results

Finished foam pieces weigh very little, making them easy to move, hang, or ship. This is especially important for trade shows, film sets, and traveling displays.

Technical Specifications

Industries We Serve

At Istar Machining, we provide CNC cutting foam services for many different industries:

• Film and Television – Props, set pieces, special effects
• Architecture – Scale models, presentation displays
• Retail – Store displays, product showcases
• Engineering – Prototypes, testing models
• Education – Teaching aids, demonstration models
• Packaging – Custom protective inserts
• Aerospace – Lightweight test models
• Events – Trade show displays, promotional items
• Art – Sculptures, installations, gallery pieces

Why Choose Istar Machining for CNC Foam Carving?

1. Expert Team – Our technicians have years of experience with foam carving
2. Quality Equipment – We use professional-grade CNC machines for best results
3. Material Knowledge – We’ll help you select the perfect foam for your needs
4. Attention to Detail – Every project gets careful inspection
5. Full-Service Options – From design help to finishing and assembly
6. Competitive Pricing – Great value without sacrificing quality
7. Quick Turnaround – Fast service when you need it