[Design and Technology] Modelling foam in CNC machining & Vacuum Forming

[Laura Murphy]

Thanks David – and I just heard that Tony is coming to the conference as a trader, so that’s great news.

Lx

From: destech-bounces at edulists.com.au [mailto:destech-bounces at edulists.com.au] On Behalf Of DAVID FLETCHER
Sent: Tuesday, 17 March 2015 11:33 AM
To: DESIGN & TECHNOLOGY TCHRS MAILING LIST
Subject: [Design and Technology] Modelling foam in CNC machining & Vacuum Forming

Handy advice from Tony Pugatschew about type of FOAM to use in VACUUM FORMING, and CNC MILLING.

David Fletcher
Secretary,
DATTA.Vic

From: esnet [mailto:esnet-bounces at iiate.asn.au] On Behalf Of Tony Pugatschew
Sent: Tuesday, 17 March 2015 10:41 AM
To: 'Kurt Simpson'; 'ESNET @ iiate'
Subject: Re: [esnet] Modelling foam

Dear Kurt,
You will need POLYURETHANE foam.  This is different from the normal POLYSTYRENE foam. Differences should be covered in Plastics 101.
Polyurethane will endure the higher temperatures used in vacuum forming.

We use a building product that is very dense and can be machined to a very smooth finish. It is called MULTIPANEL and sourced from building suppliers. The safety and MSDS documentation is extensive due to the use in this industry. It is non-toxic but you have to minimise dust creation. Available in different thicknesses and can be glued together. Again, adhesive info is available from suppliers.

If you are using a CNC mill to make the form you  cannot hold it down with double sided tape.  I hot glue the foam to a piece of acrylic that is then taped to the bed. No problems clamping it but  you have to minimise the compressive force.

Machine as fast as your machine can handle it with a  ball nose cutter for an excellent smooth finish.

Follow on Russels suggestion re Solid Solutions but ask for polyurethane.

In terms of polystyrene – I did have success forming over it if I soaked the foam in water and then sprayed the form with a water mist after vacuum application. You have to be quick and only works if you have have thin plastic for the form. PETG works the best.

Hope that helps.
Tony Pugatschew


From: esnet [mailto:esnet-bounces at iiate.asn.au] On Behalf Of Kurt Simpson
Sent: Tuesday, 17 March 2015 7:29 AM
To: ESNET @ iiate
Subject: [esnet] Modelling foam

Hi. Could anyone point me in the direction of a supplier for modelling foam that would be suitable to use as the pattern material for a vacuum former? Are there any non-toxic options available?

Thanks,
Kurt
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