How to Fabricate Foam Props Figurines

Wanted to share with you the process of creating 3D foam props, small sculptures figurine characters for a customer, for demonstrating internal safety procedures at the work place.

The theme was Potato Head Cocoa Beans.

The customer provided us with a photo and a PDF file only, we converted the PDF to a 3D CAD file to be able to machine / mill it on our CNC router


We sanded al the excess EPS material and made it smoother, then coated the Potato Head figurines with Epoxy hard coat shell and primed it.

The epoxy gives it a nice protective layer and also crates a smoother finish.


Next step - Painting! This is now a hard hat zone - Safety First!



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