Machining polyurethane upholstery foam

[David D.]

Anyone tried machining open cell seat foam? What cutter worked for you?

 

I'm being rushed to create a prototype seat foam shape, no time for our molder to do the usual. I've seen videos and read technical articles telling me that others have had success, even without the messy step of freezing into a block of ice prior to machining. I'm just hoping to save my employer some money by using an appropriate cutter from the beginning.

 

Thanks All.

[taperlength]

I shape seat foam by hand with a coarse grinding wheel, have to take light cuts.

[RaiderX]

sharp 2 flt HSS end mills work but is abrasive so sharp carbide is preferred, no honed edges.