Plastazote LD45 Closed-Cell Polyethylene Foam

Splitting

Taking a thicker foam sheet, typically 100mm thick, and splitting or slicing down to a thinner sheet. Tolerances as fine as 0.2mm. A high vacuum bed holds the foam steady, then moves it across a fine, consistently sharpened blade.

Bandsaw

Used for creating a consistent, straight cut to alter the width or length of foam sheets, slabs, or blocks.

CNC Routing

CNC routing machines remove material from a secured foam sheet to create any shape or beveled edge required. A specialized router bit, chosen for quality foam conversion, follows a precise path programmed by engineers. Intricate patterns can be machined into the foam.

CNC Water Jet Cutting

A more affordable CNC method, cutting through thick material in a single pass with pressurized water, reducing production time and cost. Small radius cuts are possible as the thin stream removes fine amounts of material. No variable depth is available.

CNC Knife Cutting

Fast and precise, reducing machine time and job cost. Limitations include limited cutting depth (based on knife length) and the need for cuts to penetrate fully through the foam. Various depths can be achieved by layering, adhering, or butt welding cut foam pieces.

CNC Wire Cutting

Cuts 2D profiles from foam sheets or slabs up to 2.4 meters in length and any height, often referred to as a profile cut.