CNC Foam Routing Services

CNC foam routing is a cutting-edge process that uses computer-controlled machines to cut, shape, and carve foam materials with amazing accuracy. At Istar Machining, we use special tools that spin very fast to create perfect shapes in foam. Our machines follow exact computer designs to make your ideas come to life.

Think of it like a super-smart robot that can carve foam into any shape you need – from simple boxes to cool 3D designs!

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Supports uploading of the following file formats: .STEP .STP .SLDPRT .STL .IPT .3MF .3DXML .PRT .SAT .DXF .X_T .X_B .JT .CATPART

20+ Years

Istar Machining's years in the industry

300,000 square feet

The size of Istar Machining's factory

300 CNC machines

Our CNC equipment count

1000 skilled workers

Istar's number of skilled machinists/operators

Materials We Work With

We can work with many different kinds of foam:

Foam Type	Best Uses	Special Features
EPS Foam (Expanded Polystyrene)	Packaging, insulation, models	Lightweight, inexpensive, good insulation
Polyurethane (PU)	Furniture, props, cushioning	Flexible to rigid options, durable
Polyethylene (PE)	Packaging, water-resistant applications	Water-resistant, chemical-resistant
Zotefoam	Aerospace, medical, high-performance	Closed-cell, lightweight, pure
Gator Foam	Signs, displays, models	Rigid, smooth surface, paintable

Need a special type of foam? Just ask! Our CNC foam machining service experts can help you pick the right material for your project.

Our CNC Foam Routing Equipment

At Istar Machining, we use top-of-the-line machinery to deliver perfect results:

3/4/5-Axis CNC Machines: Our multi-axis machines can create complex 3D shapes and smooth curved surfaces
High-Speed Spindles: Running at up to 24,000 RPM for clean, precise cuts
Vacuum Hold-Down System: Keeps foam pieces firmly in place during cutting
Dust Extraction: Keeps your parts clean and ready to use
Advanced Tooling: Special bits designed just for foam cutting

For even more complex shapes, check out our 5-axis routing services!

What We Can Make With CNC Foam Routing

The possibilities are almost endless! Here are some common things we make:

Aerospace Industry

Lightweight insulation panels
Drone components
Scale model aircraft
Composite molds

Marine Applications

Buoyancy aids
Dock floats
Boat hull molds
Lightweight boat parts

Architecture & Construction

Scale building models
Custom crown molding forms
Fireproof insulation boards
Acoustic panels

Entertainment & Arts

Movie props
Theater set pieces
Cosplay armor and costumes
Art installations
Museum displays

Packaging & Protection

Custom packaging inserts
Electronics protection
Medical device packaging
Shipping containers

For complex parts that need extreme accuracy, our CNC prototype machining service is perfect.

Why Choose Istar Machining?

Amazing Precision: We can cut foam with accuracy of ±0.005″ (that’s thinner than a human hair!)
Fast Turnaround: Get your parts in 1-5 days
Cost Savings: Our automated processes save you money
Material Knowledge: We know exactly how to work with each type of foam
Complete Service: From design help to finished parts, we handle it all

The CNC Foam Routing Process

Here’s how we turn your ideas into real foam parts:

Design: Send us your CAD files (we accept STL, DXF, STEP formats)
Review: Our experts check your design and suggest improvements
Material Selection: We help you choose the best foam type
Programming: We set up the CNC machine with the right tools and speeds
Cutting: Our machines precisely cut your design
Finishing: Optional sanding, sealing, or painting
Quality Check: We inspect every part
Shipping: Safe packaging and fast delivery

Need help with your design? Our 3D CNC routing team can bring your ideas to life.

Special Applications

Custom Packaging

We make foam inserts that perfectly fit your products, keeping them safe during shipping and storage. Our foam cavities match your product’s exact shape.

Architectural Models

Architects love our ability to create detailed building models from their CAD designs. We can make scale models of buildings, landscapes, and city blocks.

Props & Displays

Movie studios, theaters, and museums rely on our foam props and displays. We can make everything from fake rocks to entire set pieces.

Prototypes

Test your product ideas in foam before making expensive metal parts. Our CNC foam milling service is perfect for this.

Technical Specifications

Parameter	Capability
Maximum Workpiece Size	8′ x 4′ (standard), larger pieces possible
Minimum Feature Size	0.03″ (0.75mm)
Surface Finish	Smooth, ready for paint or coating
Tolerance	±0.005″ (0.127mm)
Turnaround Time	1-5 business days (rush service available)
File Formats	STL, STEP, DXF, CAD/CAM

Industry Applications

Aerospace

Aerospace companies trust Istar Machining for foam components that meet strict industry standards. We make lightweight insulation panels, test models, and more with our aerospace CNC machining services.

Marine

Boat builders use our foam parts for prototypes, molds, and finished components. Our foam parts are perfect for marine applications where weight matters.

Architecture

Architects and model makers trust us to turn their designs into perfect scale models. Our foam models help clients visualize buildings before construction starts.

Entertainment

Film studios, theaters, and theme parks use our foam props and set pieces to create amazing visual effects at a fraction of the weight of real materials.