Companies are using CNC hot wire foam cutters to cut any 2D foam shape that only requires a flat surface. When there is a need to make a 3D shape, a CNC router should be used. A CNC router will machine any 3D shape. It is a 3-axis machine, which means that it moves in 3D space diagonally and in curves, in movements that resemble milling or carving. The router can create 3D designs from numerous types of materials, including:
EPS foam, urethane foam, aluminum, light wood, acrylics, plastics, and polycarbonate and ABS. The machining process involves creating a 3D model using 3D CAD software, then bringing this model into a 3D toolpath that will tell the router the shape size, resolution, cut directions, depth of cut , etc.
The shapes that can be created with a router are almost limitless.
Applications and Industries:
* Automotive – Large scale cars, boats, airplanes
* Aerospace – UAV Models
* Architectural: any 3D architectural form
* Fine arts, sculptures, statues
* Marine – Ships, ship models
* Museums: 3D displays, faces, statues.
* Navigation – Topographic Maps
If you have a 3D model that you want to design and it is too large or too thick to machine due to cutter height or length restrictions or because the foam material is not thick enough, the shape can be cut into sections. Each slice will be machined separately using the router and then the pieces can be glued together. The machined parts can then be sanded and coated with a protective hardcoat and painted, which will also remove any visible grooves due to gluing. Routers can also be used to create molds that can then be poured with concrete or polyurethane and other casting materials.
CNC routers range from a few inches of work area to 50 feet in length.
Each router uses a spindle – it is the motor that is doing the actual cutting. Router spindles range from 1 HP to 20 HP and more, and can hold milling cutters (the drill) from 1/16″ to 2″ and more.
Different materials require different cutters and different cutting speeds. The denser the material, the slower the cutting speed.
If you need to create a foam shape design that is large or even full scale, you can take a small model, scan it with a 3D scanner, and then transport it to the CNC router for machining, using specialized cutting software that generates the part file. . Using the scanner allows you to convert any normal model into a life-size design. Any model can be scanned: a face, a sculpture, a toy car, a train, a ship, an airplane and anything you need bigger. You don’t have to visualize and imagine what the 3D model will look like – the scanner does it for you.
