Foam CNC Milling Service

Foam CNC milling is a computer-controlled cutting process that turns blocks of foam into custom 3D shapes. At Istar Machining, we use advanced 5-axis CNC routers to carve foam materials with amazing accuracy. Our precision CNC machining creates perfect foam parts every time – no mistakes!

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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

Why Choose Our Foam CNC Milling Service?

Our foam CNC milling service helps you make exact foam parts for many different projects. Here’s why customers pick Istar Machining:

Super accurate cuts (within 0.005 inches)
Works with many foam types
Fast delivery in just 2-4 days
Handles big projects up to 48″ x 96″ x 24″
Makes smooth surfaces that need no extra work
Saves money compared to hand-cutting

Materials We Work With

Foam Type	Density Range	Best Uses	Special Features
Polyurethane	10-40 lb/ft³	Prototypes, tooling	Many densities available
EPS (Expanded Polystyrene)	1-3 lb/ft³	Props, packaging	Very lightweight
XPS (Extruded Polystyrene)	1.5-3 lb/ft³	Models, signs	Smooth surface
EVA (Ethylene-Vinyl Acetate)	2-12 lb/ft³	Padding, cases	Flexible, durable
Fire-retardant foams	Varies	Public displays	UL 94 certified
REN Shape®	40+ lb/ft³	Tooling boards	Heat-resistant

Need help picking the right material? Our team can help you choose the best foam for your project.

How Our Foam CNC Milling Works

Our CNC milling process uses G-code programming to control cutting tools with great precision. Here’s how we turn your ideas into real foam products:

Send us your design (we accept STEP, STL, IGES files)
We check your files to make sure they’ll work perfectly
Our team sets up the CNC program for the best results
We secure the foam block on our 5-axis foam router
CNC machining creates your exact shape
We finish the foam surface to your specifications
Quality check ensures everything meets standards
Your foam parts are packed and shipped

Industries We Serve

Packaging Solutions

We create custom foam packaging that protects your products perfectly. Our CNC-milled foam inserts hug your products like a glove, with anti-static options available for electronics.

Aerospace Tooling

Our aerospace CNC milling service creates lightweight, heat-resistant foam molds for composite layups. These tools work 80% faster than aluminum tools at just 1/3 the cost.

Film and Entertainment

Turn concept art into reality! We can make dragon scales, alien terrain, or detailed architectural ruins faster than hand-sculpting. Many Hollywood studios use our services.

Architectural Models

Show clients impressive 3D building models with super accurate details. Our XPS foam milling creates lightweight, easy-to-transport scale models for presentations.

Medical Prototyping

Test ergonomic designs with rigid foam before moving to production plastics. We offer FDA-compliant materials for medical device prototypes.

Composite Molds

Create seamless molds for boat hulls, car panels, or art installations. Our precise CNC milling eliminates air gaps in composite layups.

Technical Specifications

Maximum Part Size: 48″ x 96″ x 24″ (we can do larger projects too)
Standard Tolerances: ±0.005″ (±0.002″ available for special projects)
File Formats: STEP, STL, IGES, OBJ, SolidWorks
Lead Time: 2-4 days standard (24-hour rush service available)

Benefits of Foam CNC Milling

Precision Control

Our foam CNC milling service delivers ±0.005″ accuracy, making parts that fit together perfectly. This level of detail is impossible with hand-cutting methods.

Material Flexibility

From soft packaging foam to dense tooling boards, we work with every foam type. This makes our service perfect for any industry need.

Speed to Market

Get your foam products in just 2-4 days, much faster than 3D printing for large items. For urgent projects, our rush service delivers in 24 hours.

Cost Efficiency

Foam tooling costs 60-70% less than metal alternatives. Our CNC routing foam service uses advanced nesting techniques that save material and reduce costs.

Common Applications

Custom Packaging Inserts

Protect delicate products with foam inserts shaped to fit exactly. We create:

Electronics packaging
Medical device cases
Tool organizers
Camera equipment protection
Musical instrument cases

Prototype Development

Test your product designs quickly and cheaply with foam models before final production. Perfect for:

Product concept visualization
Ergonomic testing
Design validation
Marketing displays
Client presentations

Architectural Visualization

Show off building designs in 3D with detailed foam models:

Building scale models
Landscape topography
Urban planning displays
Interior design mockups
Exhibition displays

Tooling & Molds

Create lightweight molds for composite materials:

Fiberglass boat hulls
Carbon fiber panels
Concrete forming
Vacuum forming molds
Pattern making

Why Choose Istar Machining

When you need foam CNC machining, Istar Machining offers:

Expert Operators: Our technicians have years of experience with foam milling
Advanced Equipment: 5-axis CNC routers for complex shapes
Quality Materials: We source the best foam for every project
Competitive Pricing: Get great value without sacrificing quality
Fast Turnaround: 2-4 day standard delivery, rush options available
Design Support: Help optimizing your designs for CNC production

How to Order

Getting started with our foam CNC milling service is easy:

Contact us with your project needs
Send your CAD files for a free quote
Approve the quote and project timeline
Production begins within 24 hours
Receive your foam parts in 2-4 days

Get Started Today

Ready to bring your foam project to life? Contact Istar Machining today for a free quote on our foam CNC milling service. Our team is ready to help with everything from simple packaging inserts to complex aerospace tooling.