clam shell ceiling

[Greg VN]

I have a project that we need to do that I am looking for a material that we can use to machine and install in a painted ceiling in a clients dining room.

It will be 6 panels about 4' x 7' shaped like a clam shell.

We considered using mdf but the panels will be as thick as 10" in some areas which means it will be very heavy. Does anybody know of a light weight material that can be machined, retain good detail, and have the ability to be painted.

 

Thanks for any help

[Mike Gates from Barefoot CNC]

You should be able to use some type of high density foam. I saw some parts cut of some this past weekend at IWS that were very detailed and the surface finish was quite smooth. They should easily be primed and painted. You may be able to get some samples to test from a foam supplier in the area.

[Greg VN]

I use 1 & 2 lb. foam to test programs on occasionally but it is too porous. I will make a few calls and see if I can find some high density foam.

Thanks Mike

[Surface]

General Plastics sells a foam available in various thickness and densities. Easy to machine, holds detail well and can take paint. If you call them, they can send you samples of the material. I think it's called Last-a-foam.

[Greg VN]

Surface, I called General Plastics and they are sending me some samples of 10 lb. foam to try out.

Thank you for the tip

[Rick Henrickson The Boeing Co.]

4lb foam should be just fine

[Colin Gilchrist]

Greg,

 

In case you didn't already know, the specification is for the density per cubic foot. So 10 lb. foam is 10 pounds per cubic foot.

 

We use 20 lb. and 40 lb., and I think even the 20 lb. is quite porous, unless you can coat it with something. The 40 lb. foam is much closer to the consistency of MDF and would probably require less paint, but is obviously weighs more.

[Matthew Hajicek - Singularity]

Sounds to me like you might be better off machining MDF and then thermoforming ABS or similar over it. Unless that bulk serves some function you're better off without it.