There are many instances where high-density foam may be useful in manufacturing. One obvious area is shipping, where you may have to provide shockproof or custom-fit packaging. Another is when building large scale prototypes that require structural support and good appearance, but not necessarily production-intent materials for all components. In these situations, the ability to make an accurate model of a part out of foam instead of metal or plastic can save time, cost, and weight.
High-density foams are easily handled by CNC precision machining. However, since foams vary in specific material, and the ideal tools for cutting them also have some differences, you need a provider who can take these factors into consideration. A skilled machinist will understand the differences in tooling and the spindle speed and machine feed that are used to mill each material, so they can ensure the products are milled safely and accurately.
The Types of Foam
Polyethylene and polyurethane are common foam materials types, but they differ in their weight and density. Simple hand tools and even rotary tools are often not enough for cutting them when complex shapes and small details are part of the design. Many polyurethane foams are high-density, and a router cutter is useful. But routing cutters can tear, or even melt, foams, since they often have such a low melting temperature, and they do not cut it correctly. That can negatively impact the precision of the final product. An experienced CNC provider will know what type of foam to recommend for your application and how to operate and program the best CNC machine for the task.
Using the Right Machine
Multipurpose CNC machines are helpful for prototyping and small runs. That might include instances where you need foam in a specific shape to meet the specifications of the project. Examples include unique musical instruments and sound equipment that need careful packaging to avoid damage. These machines are also useful for making one-of-a-kind or small volume parts for larger models.
Accuracy is vital for CNC precision machining services. It is critical to program the paths correctly with the appropriate cutting tools. Doing so reduces inaccurate cuts and wasted materials and makes sure the product is dimensionally accurate. With today’s CAD/CAM software it is easy to make exact replica of parts, or even make mating parts or packaging that fit your parts perfectly.
The size of the part is also a consideration when selecting a CNC machine, as being able to mill the entire part from one piece of foam is more desirable than making multiple sections which have to be glued together. Parts can range from something that fits in the palm of your hand, to an entire full-scale vehicle model.
Choose the Best CNC Precision Machining Services
Using form for portions of your prototype model, for structural support, or even to protect an item for shipping is a great solution in many situations. However, having the knowledge of how best to machine the foam material to meet your needs is critical to the success of the final product. If you want help in using high-density foams in your design and manufacturing, consider prototype CNC machining and contact Global Technology Ventures Inc. today.
