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Foam CNC Machining
Foam CNC machining is a cutting-edge process that uses computer-controlled tools to shape foam materials with amazing accuracy. At Istar Machining, we use special machines to cut, carve, and shape different types of foam into exactly what you need!
- Save money - cheaper than metal tools
- Get it fast - no long waiting times
- Super accurate - precise cuts every time
- Make one or thousands - works for any size project
Get a New Quote
Supports uploading of the following file formats: .STEP .STP .SLDPRT .STL .IPT .3MF .3DXML .PRT .SAT .DXF .X_T .X_B .JT .CATPART
- All uploads are secure and confidential.
23 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 machine many types of foam at Istar Machining, including:
- EPS foam – great for packaging and models
- XPS foam – stronger than EPS, good for signs
- Polyurethane foam – perfect for molds and prototypes
- High-density tooling boards – for strong, durable parts
Industries We Serve
At Istar Machining, we provide foam CNC services to many different industries:
Our Foam CNC Machining Services in Detail
Let’s look closer at what foam CNC machining can do and how Istar Machining makes it happen!
Material Compatibility
At Istar Machining, we work with foams from super soft (1 lb/ft³) to very firm (40 lb/ft³). This means we can make anything from soft packaging to sturdy molds.
Real-world example: We recently made lightweight foam cores for an aerospace company that needed testing models. The foam was light enough to handle easily but strong enough to stand up to wind tunnel tests.
Precision and Accuracy
Our machines can cut foam with amazing accuracy – as precise as ±0.005 inches! That’s about as thick as a piece of paper.
Did you know? We use special tools for each type of foam to get the cleanest cuts possible.
Size Capabilities
Need something big? No problem! Our machines can handle foam pieces up to 12 feet long, 6 feet wide, and 4 feet tall. That’s bigger than most cars!
Cool project: We once made giant foam letters for a movie premiere that were 8 feet tall but light enough for two people to carry.
Cutting Speed
When you need things fast, our foam CNC machines can deliver. We can process hundreds of foam sheets each day for high-volume jobs.
Time-saving fact: Foam CNC machining is about 5 times faster than hand-carving the same shapes.
Advanced Capabilities
Our 5-axis machining equipment can create complex shapes with undercuts and detailed features that simpler machines can’t make.
Amazing application: We made detailed automotive seat prototypes with ergonomic curves that helped a car manufacturer test comfort before making expensive production molds.
Complete Comparison Table of Foam CNC Machining Parameters
Product Parameter | Usage Scenarios | What This Means For You |
Material Compatibility | Car prototypes, airplane parts | We can machine the perfect foam for your project – from soft packaging to tough molds |
Tolerance Range | Wind tunnel models, precise tools | Get accuracy down to ±0.005″ – perfect for technical projects |
Max Workpiece Size | Building models, movie props | Create huge pieces up to 12′ x 6′ x 4′ – bigger than a car! |
Cutting Speed | Mass-produced packaging | Get 500+ foam pieces per day for big orders |
5-Axis Capability | Complex molds, curved shapes | Make intricate designs with undercuts and flowing curves |
Hot Wire Integration | Theme park props, insulation | Get smooth cuts on EPS foam for perfect finishes |
Dust Management | Medical parts, clean rooms | Our machines capture 99% of dust for clean operations |
Cost per Part | Movie props, startup prototypes | Start at just $85 for custom foam parts |
Software Compatibility | Copying existing parts | We can work from your 3D files or scan physical objects |
Surface Finish | Store displays, show booths | Get smooth, polished edges ready for display |
The Istar Machining Advantage
What makes our foam CNC machining service special? Here’s why customers choose us:
Technical Expertise
Our team knows everything about foam machining. We can help you:
Choose the right foam type for your project
Design parts that will machine well
Solve complex foam cutting challenges
Quality Control
We check every part using advanced measuring tools to make sure it matches your specifications exactly.
Fast Turnaround
Need it quick? We offer:
24-hour service for urgent projects
Standard 3-5 day delivery for most orders
Scheduling options for production runs
Cost Efficiency
Our nesting software fits parts together to use materials efficiently, saving you 15-30% on material costs.
Our Foam CNC Machining Process
Here’s how we turn your idea into a finished foam part:
Design Upload
Send us your STL, STEP, or IGES files
CNC Programming
Our experts program the cutting paths
Machining
Computer-controlled tools shape your foam
Finishing
Smooth edges and apply coatings if needed
Quality Check
We verify every dimension
Ready to Start Your Foam CNC Project?
Getting started is easy! Just follow these simple steps:
- Send us your design files
- Get a free quote
- Approve your project
- We’ll machine your foam parts
- Receive your finished pieces
Frequently Asked Question
Think of it like a super-smart robot that can carve foam into any shape – from simple blocks to complex 3D designs. This is perfect for making prototypes, models, packaging, and many other cool things.
It depends on the foam type. For XPS foam, we can cut details as small as 0.06 inches. For polyurethane foam, about 0.12 inches is the limit.
Most projects are done in 3-5 business days. Rush orders can be completed in 24 hours for an extra fee.
Hot wire cutting uses a heated wire to melt through foam, which is fast but limited to straight cuts or simple curves. CNC routing uses spinning cutting tools that can create much more complex shapes with detailed features.
Yes! We can apply special coatings to foam parts that make them weather-resistant. We can also recommend foam types that naturally resist UV damage.
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