CNC Router Programming – Foam

A leading closed cell foam manufacturer for insulation and assemblies of aircrafts and automobiles.

A leading manufacturer and supplier of closed cell foam products used as insulation for various parts and assemblies of aircrafts and automobiles needed help forming a foam part with pockets in irregular shapes. For formulation, the client uses various densities of polypropylene and polyurethane foams, which remain light in weight, fire retardant, absorbs less water, highly chemical resistant, and smooth.

Project Details

Client Challenge

The client needed to make a foam part with pockets as well as varying radii and tapers to fulfill its CNC router programming project. Typically, the client makes these types of parts in thermoforming molds, but the cost of producing a mold for this part would be high due to its various intricate features. Rather than using a mold to form this part, the client opted to use a CNC router machine for part formation.

Our Solution

One of our RGBSI engineers studied the various parameters of the foam part’s features like the minimum radius, taper angles, various steps, and pockets. After defining the process for cutting one pocket at a time, our engineer created the tool paths to completely machine the CNC router programming part. After, the tool paths were verified through a simulation study we conducted, a suitable CNC router program was made to cut the foam while holding it in a vacuum fixture.

Result