Machinable Foam

[PBpaul]

Hello all:

 

A couple of years ago, we took small wooden carvings from a local artist, digitized them, scaled them up, and routed them (also in wood) with our CNC router. These upscaled parts were then molded and cast in bronze. Now the same artist is interested in another project that could be physically larger and he's seen other artist's work scaled up and machined in foam. I need to know what kind of foam is suitable for this kind of CNC routing work and who is a good source. Any advice would be appreciated. His work in wood was highly detailed but I suspect that the foam work would not be tremendously detailed.

 

Paul

[BOBP]

check here

http://www.freemansupply.com/PolyShapeIIPolyure.htm

[Nils N]

Paul

Here's another one to check out

http://www.generalplastics.com/

[crazy^millman]

I would look at Ren-Shape material. A contact might be: Walco Website

I like the way it machines and it is very dense and some have a high heat tolerance as well.

 

HTH

[lynnz]

You could also get Ren-shape materials from the Freeman supply link in BOBP's post above.

 

Good luck

lynnz

[Bruce Kanzelmeyer]

I use Renshape almost every day for proto tooling for thermoforming. Be careful if using on a mill--it is very "dusty" and gets into everything--its also abrasive so you need a pretty good vacuum system. We cut it without coolant on a router and built a somewhat enclosed area with negative air pressure vac system to keep the dust from getting everywhere! Good luck--it machines beautifully and is easy to repair (bondo), sand, etc. It holds up to 400 degrees for short thermoforming runs.

[PBpaul]

Much thanks to all. As far as the Ren-Shape material goes, if you don't mind my asking, which ones do you use? I see they have a bunch of different densities. I'm guessing the higher the density, the higher the cost, too.

 

Thanks- Paul

[mike.b]

they talk about this stuff alot at the shopbot forum as they are all woodworkers and signmakers and like to test out their programs on foam.

[cadcam]

Do you want to do some thing like this:

http://www.ppcadcam.com/html/tounge_scraper.html

then go to Foam tooling on left bar.

[Trevor Bailey]

I gave up on Ren for forming stuff...prototyping, etc....

 

Check out these guys. They offer a material called HG3000, which is a plastic but cuts like paper. Hard to explain, but well worth a look. Cheaper than Ren too. Especially since you can purchase the materials and mix it yourself with little effort.

 

As for the Ren, if that is what you will go with, stick with the 450 board. It is mid-range for density and pricing. A full board, 60 x 16 x 2 will be around $400.

[htm01]

we used to make models out of butterboard good stuff

[lynnz]

I agree with Trevor. We use 450 and 460 boards.

The 5020 is the low density stuff which is slightly porous kind of like foam.

You might contact Freemans and request a small sample of the various types of boards.

 

lynnz

[John Summers]

MDF (medium density fiberboard) works amazingly well for something that cheap. It even comes in 1-1/2 thickness, but only at builder's supply stores in our area.

[Trevor Bailey]

MDF is good, but depending on how much you will be machining, make sure that you have a good vacuum system set up.

[gavetta]

We use OBO Modulan from McCausey Lumber

www.mccauseylumber.com

It cuts a little better then ren with a little less dust (depends on the density). 1-800-365-9663 is their number.

[PBpaul]

Again, thanks to all for all the info.

 

We do use MDF but weight is a problem. Also, I think it is "Case Hardened" and if you cut a thin layer off only one face, the sheet is stressed such that it wants to become bowl-shaped where the non-machined face becomes concave.

 

A couple of the links you all supplied offer samples and that's where I'm headed now.

 

PBPaul

[Greg VN]

Mdf does cut good with one downside - it will dull a cutter fast. Some shops that make cabinet doors will have one set of cutters for mdf and one set for wood. I use it myself once in a while.

It is easy to glue up into a big block if you need to.

[PBpaul]

Cadcam:

 

If/when you see this.....I did click on your link and look at the pictures but did not see any links or information regarding what foam was being used. Can you shed some light?

 

PBPaul

[cadcam]

Hi Paul it is standard Styrofoam, there is a company that sells it in Sylmar Cali. I would have to get you the name.

 

Boy does that stuff go every were when you cut.