Friday, December 18, 2015

Foam Machining Projects

Foam cutting and machining services

EPS Foam machining of 1LB EPS foam

The car was machined using our CNC router, glued and then 
coated - using a simple drywall mud

Now, a bit of sanding

And almost perfect results

Car prop is all smooth now

Easter Island Statue made from 1LB EPS foam
Machined from EPS using our CNC router

Easter Island statue and a dragon by its side

The foam is coated with Styrospray 1000
which is a polyurethane coat, then painted with stone-like paint

8' Totem Pole project
8' Totem Pole - machined from EPS foam using our CNC router
Still raw foam - not coated

And below - Coated with polyurethane and painted

Machining EPS column

Fabricating BAMScape Berkeley Art Museum Exhibit
Raw 1lbs EPS blocks ready to be machined

150 Curved 1LBS EPS machined Modules.
Each module is about 8'long 4'high 20"wide 3/8" thick plywood

All 150 modules laminated with plywood 
Installed at Berkeley Art Museum - 1550sf display

EPS foam props- bottles
EPS foam props- bottles
Concrete molds - EPS foam molds
Prototyping services - XPS foam

Coated with polyurethane

See how we fabricated Berkeley Art Museum BAMScape Project

Tuesday, December 1, 2015

How We Fabricated Berkeley Art Museum Exhibit with Architect Thom Faulders

The Berkley Art Museum project took 3 month to finish
With more than 160 pieces, most 8' in length.
3 months from start to finish

We started out with over 100 blocks of EPS 1LB foam

Foam being cut on the CNC hot wire foam cutter

EPS blocks after being cut on the CNC Hot wire

Each piece is covered with 1/8" plywood on both sides
and 1/4" wiggle wood from the top

Each piece is primed

And then Painted

Pieces placed, and mounted to one another

We glued anti slip pads onto each unit

The end result is an interactive Living Art, "serving as a site for rest, relaxation, and study, as well as a platform for the experience of live performance and multimedia events".

Fabricator - WeCutFoam
1248 Birchwood Drive
Sunnyvale, CA 94089

Monday, November 30, 2015

Fabricating an Innovative VTOL Aircraft Prototype Made of EPS Foam

Fabricating an Innovative VTOL Aircraft Prototype for Elytron LLC

We, at Foamlinx LLC and WeCutFoam have collaborated with Elytron Aircraft LLC beginning of 2014 to fabricate their newly designed two-seater VTOL (Vertical takeoff and landing) aircraft. 
This was a unique and interesting fabrication process for us and it would use to create a whole aircraft that can actually fly and be functional.
We created this modern aircraft prototype by cutting and machining Expanded Polystyrene foam using our large CNC hot wire foam cutters as well as our CNC routers. 

Custom CNC Hot Wire Foam Cutter

Large Foamlinx CNC Router

The foam cores we created were covered by Elytron using carbon fiber prepmeg to produce this innovative aircraft prototype that is an airplane capable of taking off and landing as a helicopter. 

We have started working on Elytron’s aircraft design early in 2014, while given 3D CAD files.
To create some of the parts we used CNC hot wire foam cutters, while other parts were machined using CNC routers. 
Some parts were machined on a router as large as 16ft x 8ft x 4ft in size so that the parts could be made in one piece instead of in sections. 
The machines used had a high tolerance of up to 1/16”, since the parts had to be very precise in order to fit together in the final assembly.

We created 52 different parts for the fuselage and the wings using high-density EPS foam (Expended Polystyrene). 
The whole cutting and machining process lasted about a year, and was done in increments, starting in the Spring of 2014, ending in late February 2015. 

Once each batch of foam cores was done, 
Elytron laminated them with carbon fiber prepreg material 
and glued the core pieces together. 
The end result is a unique and modern two-seater aircraft prototype. 

Elytron is currently working on their 4-seater VTOL aircraft - Now that would be another great project we would love to be involved in.
Here is Elytron's website
Take a look at their YouTube Video 

To see more of our foam creations visit us at
Like our Facebook Page
See our Instagram Page
Visit us on Twitter