CNC Foam Milling Services
in Los Angeles


CNC Foam Milling
and Hand-Sculpting

Quick turnaround on 5-axis CNC foam milling or foam sculpting services, in EPS Styrofoam or HDU Foam. Ideal for large custom parts, display pieces, and mold tooling for concrete or plaster molds.

Overview

Applications

How to Order


Foam Milling and Sculpting: Overview

Summary: What is Foam Milling and Sculpting?

Foam Milling is the process of producing a physical part made of foam material, using a computer-precision 5-Axis CNC mill to carve the part from a block of foam. This process requires a 3D Model CAD file in any of the following file formats: STL, OBJ, STEP/STP, or IGES/IGS.

Foam Sculpting is the process of hand-sculpting foam to achieve a finished physical result that closely matches image references provided by the customer. Hand-sculpting foam is less precise than CNC milling foam, but is perfectly suitable for most types of display pieces, landscapes, or any objects which don't require engineering precision.

How long does it take?

Most single-part orders are completed within 2-4 days after production begins. Large, oversized parts or orders with high quantities of parts may take longer. All price quotes are given with an estimated lead-time included.

What foam materials do you have?

Two options: EPS Styrofoam and High-Density Urethane Foam (HDU).

EPS Stryofoam is an economical option for general-purpose foam models with low complexity, while HDU Foam is significantly stronger and ideal for parts which require high definition and sharply-carved surface detail.

What's the difference between CNC Milling and Hand-Sculpting?

If you have a CAD file, then your parts can be produced using a computer-controlled 5-Axis CNC mill, which carves your part with high-precision based on the three-dimensional data in your CAD file. CAD files should be in one of the following file formats: STL, OBJ, STEP/STP, or IGES/IGS.

If you don't have a CAD file, then an artist can sculpt your foam parts based on your provided image references. The detail will be accurate to the eye, based on the sculptor's interpretation of the provided image references.

If you don't have a CAD file but do require the machine-precision of a 5-Axis CNC mill, we offer 3D Design services to create the CAD files required for this process, based on drawings/dimensions/images that you provide.

How large (or small) of a part can you make in foam?

Foam milling is a good option for producing parts which otherwise exceed the standard capabilities of 3D Printing. If your model is less than ~[12" x 12" x 12"], then this is probably not a good application for foam milling, as 3D Printing is likely more cost-effective and will produce a stronger and more accurate part in plastic material.

There is no true maximum allowable size for 5-Axis CNC milling or hand-sculpting, since large foam parts can be built in sections and doweled + assembled together.

I need to paint + finish my foam parts. Is that possible?

We can add a polyurea epoxy spray coating to your foam parts, to give them a hard shell which can be sanded and finished. This epoxy hard coating is ~1/16" thick, and has a slightly bumpy "orange peel" texture which can be sanded down smooth to prepare the surface for painting.

Common Applications of Foam Milling

Examples Gallery

styrofoam model and eps cnc foam milling services in los angeles

Styrofoam EPS Parts

Create styrofoam models in any shape and size. This EPS foam material is lightweight and a good option for models without fine or intricate details.

foam model and cnc polyurethane foam milling services in los angeles

HDU Urethane Foam Models

Polyurethane foam is a denser, more robust material option for models which require finer or more intricate detail. Optiions inclue 4-lb and 6-lb polyurethane foam.

service for hard coating foam parts with polyurea epoxy spray in los angeles

Hard Coating

Coat your CNC foam models with a hard epoxy shell surface, so they can be smoothed and painted.

custom foam display models and painted foam sculptures in los angeles

Custom Finishing

Get fully-finished display pieces, painted to perfection with any color or style.

How to Order

Get a Quote

Provide CAD files or reference images

To get a price quote for your foam parts, submit a quote request and provide your CAD files in one of the following file formats: STL, OBJ, STEP/STP, or IGES/IGS. A project engineer will review and respond, typically within 15-30 minutes.

If you don't have CAD files, we can hand-sculpt your part based on your reference images. If you need precise foam parts made on a 5-axis CNC mill but don't have CAD files, we provide 3D Design services to produce these 3D Model CAD files for you.

Choose a foam option

Your foam parts can be made in EPS Styrofoam, or High-Density Urethane (HDU) Foam with 4lb or 6lb density.

EPS Stryofoam is an economical option for general-purpose foam models with low complexity, while HDU Foam is significantly stronger and ideal for parts which require high definition and sharply-carved surface detail.

Production and Finishing

Your foam parts are created with 5-axis CNC Milling (precise machined detail), or hand-sculpting (professional artist interpretation).

If you need a hard surface over your foam parts for painting + finishing, we can add a polyurea epoxy hard coat to your foam parts.

If you need a large part that must be built in multiple sections, we can dowel and assemble prior to delivery, or we can provide your order in separate pieces.

Let's create something.

Start working with a Project Manager, or use our interactive online platform for instant self-service.