CNC Machining Low and High Density Foams / Tooling Boards

Machined Foam/Tooling Board is an effective and popular method of creating a physical product to represent design data. It is and has been used in every industry, but is especially popular anywhere there is a need for larger models that are not overly complex and that require a high-quality surface finish. These models are beneficial in prototyping and studio mock-ups as they allow designers and engineers a physical way to observe the parts and make changes to the data before the production phase.

Common Foams Used and Why

 

1lb Closed-Cell Foam

We use 1lb density foam (similar to Styrofoam used in shipping) to mill nests that aid the bonding and shipping of SLA, FDM, and SLS rapid prototypes. A secondary function of these nests is to verify the size of the 3D Printed parts. It is common to receive requests to 3D Print a grille, bumper, or other large part that will require building it in multiple pieces. Once the pieces have been printed, they are laid in the 1lb foam material which has been CNC machined to perfectly accommodate the parts finished shape and then bonded together. The machined foam nest ensures an accurate bond and the nest can also now be used to safely transport the part to its final destination.

3lb Closed-Cell Foam

This foam is similar to the 1lb but thrice as dense making it a bit more tolerant to work with. This is one of the least expensive options for machining shell models, down & dirty properties, and simple spatial properties. However, because it is still a very light density, its applications are limited. It is not resistant to many chemicals either, so if paint is desired, latex interior paint or similar must be used.

15lb Polyurethane Foam

This density allows for finer details to be captured and is more resistant to sealers, primers, and paint. It is very easy to sand and process while still being somewhat light-weight and less expensive than denser foams. This density foam is mostly used for models as a spatial representation, and anything that requires a lot of mounting features or moving parts may require a more durable foam.

30lb Polyurethane Foam

Both 15lb and 30lb Foams are very popular in the development of Styling Bucks and properties in the Automotive & Aerospace industries. 30lb density foam captures even more detail than 15lb and is even easier to prime, paint, and finish. This density is also good for developing fiberglass and carbon fiber layup tools or vacuum form tools.

40lb (REN) Polyurethane Foam

This density is most popular with OEM Studios and professional model makers because it captures detail well and has a crisp, clean surface finish right off the CNC Machine. It can also be drilled and tapped and used for more structural components of styling bucks and show models. It can withstand more stresses and is more functional than the 30lb foam. It absorbs less primer so it dries faster and allows the model maker to apply Class A finish coats of paint in less time. It is even better for layups than 30lb because the added density allows for a better surface finish that will be ultimately be transferred over to the layup.

51lb Fixture Plank

Fixture Plank is one of the most dense and premium options available for machining. It is primarily used for Checking Fixtures in the automobile and aerospace industries. It is very stable, durable, and accurate. Many companies will choose this material over aluminum for a cost savings when building a checking fixture or assembly aid.
Ideal Technology machines all the above varieties of foam and more. We make material recommendations to our customers based upon their functional needs of the finished product. We have been machining foam for over 30 years and would be glad to help you with your next project!

iDEAL Technology Corporation provides leadership with innovative and technical services necessary in today’s global tooling market. We are dedicated to providing quality custom tooling, check fixtures and gages, rapid prototyping / 3D printing, assembly equipment, CNC machining, studio models and bucks to the automotive and aerospace industries.