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We are often asked to fabricate topographic map (topo maps) and architectural models using different type of materials, from EPS (Expanded Polystyrene) to EPP (Expanded Polypropylene) to Sintra (also known as PVC), XPS (Extruded Polystyren) and XPE (Cross Linked Polyethylene). In this post, we will explore the difference in surface finish of each material when being machined on our CNC router, focusing on the ease or difficulty of fabrication. In order to be able to compare surface finish between each of the materials, we machined the same Mt. Rainier model, using a 0.25" flat end mill. The model was divided into quarters, where each quarter represented a different level of detail achieved. For the majority of the materials especially the harder more dense ones we first used a 5/8" endmill to rough out the shape of the mountain milling the bulk of the material away before using the smaller endmill to bring the model to final depth and size. This allows us to take deeper more agressive cuts as well as saves wear on the endmill The main factor that determines the level of detail retained in a machined part is the size of the step over, often measured in percentage of the end mills diameter. Stepover is defined as the distance the cutter moves horizontally from one cutting pass to the next. A smaller stepover results in more detail and a better surface finish. We explore this idea by using three of our quadrant each with a step over of 15%, 35%, and 65% for a fine, medium, and rough finish respectively. The final quadrant shows a 2.5D topographic outline of the mountain. This is akin to the topographic maps that one might use while hiking, where each new step in elevation represents a determined amount of elevation gain. For our tests we are using a 0.25” step. Which would translate to about 1000’ of actual elevation change on the mountain. EPS (Expanded Polystyrene / Styrofoam): EPS is one of the easiest materials to machine, sculpt and work with. It is often the cheapest as well, making it is the common choice for most art and non-engineering specific projects. Due to its light density it is very forgiving on the machines, allowing us to take full depth cuts up to 8” at a time. EPS comes in 4 common densities of 1lb, 1.5lbs, 2lbs and 3lbs. EPS is 90% air, with the other 10% being small spheres tightly packed together. The heavier the variety of EPS the denser the spheres will be packed resulting in a better surface finish. This machined model shows all 4 surface finishes for comparison, using EPS. Here are photos showing the different machining finishes. Hover over each picture for more information: Top left: Fine Finish Top Right: Rough poor finish Bottom Left: Medium finish Bottom Right: 2.5D Topographic map Video of EPS being machined EPP (Expanded Polypropylene): EPP, Expanded Polypropylene is a closed-cell, beaded foam. It is from the same family as EPS (Expanded Polystyrene), the main difference being the polymer that binds the material together. It comes in 1.3lbs, 1.9lbs, 2.5lbs and 3.7lbs density options, it is a light, flexible, and durable material. It demonstrates high energy absorption and it is a great thermal insulator with high water and chemical resistance. It can be saw-cut, water-cut, die-cut, hot-wire cut, abrasive-wire cut and machined. The beads that compose EPP are much more substantial than those of EPS resulting in only a subtle difference in the surface details between the medium and fine finishes. It could even be argued that for most uses the medium finish is most desirable as the fine finish can leave behind small hair like imperfections from the numerous passes it must make. This machined model shows all 4 surface finishes for comparison, using the EPP material Here are photos showing the different machining finishes: Top left: 2.5D outline Top Right: Rough finish Bottom Left: Medium finish Bottom Right: Fine finish Here is a video of the machining process, using the EPP material. Sintra (Expanded PVC): Sintra is a lightweight yet rigid and durable expanded closed-cell polyvinyl chloride, also known as PVC. It is dent, scratch, heat, chemical and even electrical resistant and can easily be fabricated to form almost any shape. Sintra can be cut, machined, drilled and bent quite easily using ordinary tools, and can leave good surface finishes with certain cuts. In the photos below you can see multiple different shades of black resulting for the material being cut at different rates and from different directions. Take a look at this model showing all 4 surface finishes using Sintra (PVC) Here are photos showing the different machining finishes: Top left: 2.5D outline Top Right: Fine finish Bottom Left: Medium finish Bottom Right: Rough finish Here is the video showing machining Mt Rainier model using Sintra material. Extruded Polystyrene (XPS): Extruded polystyrene or XPS is a rigid closed-cell foam. It is most commonly used as insulation in buildings. The pink material is dimensionally stable, air tight, resistsant to heat transfer and has impressive compressive strength and is mostly known for its resistance to moisture absorption. Due to its manufacturing process it is prone to warp when machined into long thin parts. The material has a consistent density throughout, resulting in an even surface finish. However it is still prone to small hair like imperfections on the very fine finish. Here are photos showing the different machining finishes: Top Right: 2.5D outline Top Left: Medium finish Bottom Right: Fine finish Bottom Left: Rough finish And hee is a model showing all 4 surface finishes using XPS pink insulation material Here is a video of the machining process, using the EPP material. Cross Linked Polyethylene (XLPE): XLPE is a soft rubber feeling foam, very similar to EVA, made from Polyethylene resin. It comes in many densities and is commonly used for material packaging due to its impact resistance and high density. Due to its rubber-like characteristics it can be hard to machine when taking larger cuts, as chips do not break away as easily. This can be seen in the rough finish on Mt Rainier model. The soft rubber consistency leaves lots of a hair, stricks and residue excess material when being machined. Here are photos showing the different machining finishes: Top Right: Fine Finish Top Left: Rough finish Bottom Right: 2.5D outline Bottom Left: Medium finish Here is a video of the machining process, using the EPP material. To learn more about all the products we fabricate and our foam cutting and machining processes visit us at WeCutFoam #styrofoam #EPS #EPP #XPS #XPE #Sintra #PVC #Expendedpolystyrene #styrene #Expendedpolypropylene #cnc #cncmachining #machining #foam #foamcutting #foammachining #architecture #architecturalmodel #topographic #topographicmap #router #cncrouter #foamcuttingservices #topomap

Sintra is basically a PVC (Polyvinyl Chloride) - Expended closed cell foam core material. It is lightweight but rigid, versatile and durable board. We will try to explain the pros and cons of Sintra for indoor and outdoor uses when fabricating signs, logos and letters. So, how does Sintra material enhance decor for indoor and outdoor spaces? Matrial Charecteristics: Sintra boards (sometimes called Sentra plastic sheets) come in many colors with a low gloss smooth matte finish on both sides, ranging from 1/4" to 1" in thickness. For anything thicker than 1", layers can be glued together using a PVC glue that cures fairly fast This material is typically used for 2D shapes and has a very smooth surface finish, so it does not require any post finish, such as patching or sanding. It is denser than Styrofoam and as such, it is easily machined on a CNC router and does not require any special tools for let's say making holes in it, as opposed to acrylics. Here are some of its characteristics: Highly durable - Can withstand extreme weather conditions, resistent to moisture, UV rays and to impact Lightweight - Therefore easy to handle, install and store Versatile - Can be cut, shaped, formed to fabricate custom products and designs Somewhat Affordable Outdoor & Indoor Use: Sintra, very much like Styrofoam (Styrene) is great for both indoor and outdoor use, for signage, displays, letters, logos, exhibits and any graphic application. It can withstand extreme high and low temperatures and will not be corroded or damaged by the sun like for example a Styrofoam material. It is resistant to dents, cuts & scrapes, allowing to leave it outside under the sun for a prolong period of time while still maintaining a new polished appearance. It is also resistant to moisture and chemicals and therefore it is durable and a long-lasting material. Can it Be Combined with Other Materials? Sintra can easily be wrapped with vinyl. The adhesive vinyl print design can easily be appllied and glued to the Sintra, adding an artistic finish to it for products that are hard to be manually painted. What is it Best Used for? Sintra is everywhere. From real estate signs to tradeshows decor, photo booth props, indoor and outdoor signs for shops and companies, architectural models, automotive parts, medical devices, packaging and many more. Walking in a mall you can spot many of them on stores as well as when strolling down your neighborhood. What are the Characteristic Differences between Sintra and Styrofoam? Durability - Sintra is more durable than Styrofoam (more resistant to water, humidity, chemicals and the sun) and therefore a better choice for outdoor use when needs to be left in the sun for a long period of time. The Styrofoam might be cracked, get yellowish stains and the paint might fade, while the Sintra will most likely maintain its fresh new-looking appearance Flexibility - Sintra is more flexible than Styrofoam in a sense that it can bend without breaking. Styrofoam is rigid and cannot be bent. Printability - Both Sintra and Styrofoam are easy to print, though Styrofoam can be CNC machines or hot wire while Sintra can be machined, or cut with a knife or a saw. Sintra though has a smoother finish while the Styrofoam is a beaded and porous so its finish is not smooth. Cost - Sintra is more expensive than Styrofoam, so the Styrofoam will most likely be the material of choice when budget is a concern So, the material choice would depend on your budget and on the application of the product: indoor or outdoor use / smooth finish needed vs. finish is negligent / one time use vs. needed to last for a long time. To learn more about all the products we fabricate and all other materilas we use, visit us at WeCutFoam #sintra #sign #signs #letters #logo #logos #customsigns #sintrasigns #sintraletters #cnc #cncmachining #foam #foamcutting #foammachining

We created this bottle custom prop by using a combination of techniques and materials. CNC machining High Density Urethane foam, then coating it with Epoxy, covering it with automotoive bondo, then painting and lastly placing vinyl print and voilà - Over 6ft of Bottle Prop for our customer in Florida We started the process by machining 10lbs high density Urethane foam (also known as HDU). The whole prop is over 6ft, machined in 2 sections glued together, then sanded for a smoother finish. The cap and hanger were made by 3D printing PLA material. We made a slit at the foam to fit the cap and hanger into, then glued them in. Next phase was to place a few coats of white Epoxy hard coating. What is the add-on value of Epoxy Coating to a prop? Epoxy coating is a great agent to be used to cover foam props, giving it a shiny glossy look, adding some durability to the foam. Although it is definitely not as strong as Polyurea hard coat that is applied with a reactor spray gun and resebles plastic/corning, this epoxy coating can still add strength. It can also protect the foam a bit from being chipped or from fingerprints that might be visible if they go straight onto the painted faom without coating. Of course, if you lean on the epoxy coated prop, sit on it, stand on it or throw it on the ground it will still break, so you still have to treat it with cautios. It's not magic but eastethically speaking it is a gread add-on. But... Then this just happend. While placing the bottle on its head cap for painting, it mysteriously was knocked down. The bottle broke right next to the cap. Fast, fast, what do we do? Well, no panic that's for sure - We decided to not only fix the broken cap but also to make the whole thing stronger, so we placed Automotive Bondo What is Bondo Material & how can you implement it into custom prop fabrication? For the next stage, we coated the already epoxy coated bottle prop with an automotive grey bondo. This material, found in any hardware store, is a polyester putty produt that can be used as a filler. It is great for foam props as it is a thinner and lighter material than the texture mud we sometime use for props. This opens up a lot of possibilities for making large-scale props that are inexpensive, lightweight yet durable. To make the prop even more durable and strong, we placed wood inside the cap. We then fabricated a base plate for the bottle and painted it black. It was made as a removable plate base with 2 screws to hold it in place. Next we painted the bottle with a grey acrylic paint. We then applied a vinyl print design onto the bottle. The customer supplied us the ai art file for the print. Here are some photos of the vinyl design print glued onto the prop And here is the completed product shipped to the customer See more of our props and other things we do such as letters, logos, signs, exhibits, sculptures, prototypes and more on our website WeCutFoam #prop #props #foam #foamprops #customprops #largeprops #oversizeprops #3dprinting #bondo #coating #hardcoating #epoxy #epoxycoating #vinyl #vinylprint #cnc #cncmachining #machining #foammachining #HDU #urethane #highdensityurethane #bottleprop #automotive #bodyfiller

Fabricators of signs, logos and dimensional letters are challenged by different types of materials to choose from, including foam, wood, plastic, PVC, acrylic and metals. It seems that most sign shops and fabricators are moving into the use of foam due to its light weight characteristics, its ease of cutting, carving and handling, the possibility of hard coating it as well as its affordability. Foam letters, logos and signs can enhance the character and depth of a company message and facilitate recognition for its brand. WeCutFoam specialized in dimensional foam stage letters logos and signs Foam is all around us. There are countless products made of foam, specifically Styrofoam (also known as EPS or Expanded Polystyrene) from the crown moldings in your home to the exhibit you just saw in the museum or the cool sign on the store you just shopped at. But why would a fabricator choose to use foam when clearly, he has other choices of materials, such as metals, aluminum, plastics, PVCs Acrylics or wood. WeCutFoam specialized in dimensional foam stage letters logos and signs What Can Dimensional Styrofoam Letters be Used for? Dimensional lettering can be used as directional signage, attached to a building, office entrances or on walls for branding a message. Fabricator and sign shops have been using various materials to create dimensional foam stage letters logos and signs for retail stores, companies, stages, weddings, trade shows, conventions and for any event. But imagine making letters from metal to go on a stage. Metals and wood are considerably heavy and are inconvenient for transportation and for handling when moved from one place to another. Wood can yield a great finish look, yet is heavy as well and takes a great amount of time to work with. And plastics and PVCs are not an easy material to shape and machine. Therefore, more and more fabricators are now using foam, which is a lightweight substance as a source for creating large dimensional letters. Different Allpications of Foam Letters There are many ways in which the dimensional letters can be created. They can be left as raw white material if called for. They can be covered in matte, semi-gloss or gloss finish. The letters can be painted with specialty paintings to resemble wood, or with Faux bronze-like paint to add a metal look. They can be laminated, covered in vinyl, in fabric or even be illuminated in the back to add a light effect to them. Acrylic can be laminated in the front of the letters to match a specific logo color or to make a sign look colorful. WeCutFoam specialized in dimensional foam stage letters logos and signs Hard Coating - Durability Solution for Foam Letters Looks like acrylic cut letters have become one of the most popular choices for indoor sign letters. The acrylic is cut using a laser cutter and yields a fairly precise cut. Still, foam is the most cost-effective solution for creating signs, logo, letters and props. Since the raw foam material itself is brittle and can be damaged by water, humidity, time and sun exposure they can be protected by being hard coated. Different types of coating can be used depending on the application and use needed. They can be covered with light coating such as epoxy or rubber coating, to medium coating that can be sprayed, polished or brushed on such as Styrospray1000 or a hard coat polyurea sprayed with a reactor spray gun. The coating not only protects the letters, logo or sign, but also providing it much longer durability - They can last up to a life time once coated. WeCutFoam specializes in dimensional foam stage letters logos and signs. Is There a Size Limit to Foam Products? A block of EPS foam is typically 4 by 4 by 8 feet. Therefore, the most convenient size to create the project is up to 4 feet. However, there is no size limit while creating and fabricating letters. If they need to be larger they can be made in sections and glued together, and while sanding the glued pieces, the sim is almost completely eliminated. The letters are cut using a CNC hot wire foam cutting machine. The foam is used to add dimension to the letters. Foam letters are a great option for instance, if you want depth on a lobby wall sign. They are actually 2D that can resemble a 3D project. By giving it enough thickness, they can be "stand alone" letters on a stage. For instance, a 4 feet letter can be fabricated at 6 inches thick to be able to stand on its own, or made with a base. The foam can be cut fairly fast. A few single strokes of the hot wire melting into the material can create a letter in no time. Another advantage to the foam substrate is that it is easy to cut, mold, shape, carve and sand to a smoother finish. How to Support the Letters and Add Stability? Round letters can be made flat at the bottom to hold their own. The fabricator can create a base to the letters, either from the foam material itself, from clear acrylic and/or from plywood, therefor serving as a great support. Weights can also be placed inside the foam itself to hold the weight of the letter so that it does not tip off. If the letters need to be suspended, then clear acrylic can be placed at the back of the letter to attach it to the one next to it, creating a floating-like effect. To add even more stability, a double-sided tape can be put at the bottom opf the letters binding them to the floor or the stage and If they need to be hung from the ceiling, then eye hooks can be placed. In case they are bigger and heavier, metal rods and suspensions can be placed in them to add to the construction or heavy-duty hooks can be placed. In Conclusion Dimensional letters will help a company attract customers and convey a message in an attractive and aestethic manner. Yes, there are certainly a lot of choices out there and it can be confusing at times trying to sort them out. I would say that if you are budget conscious, but still want a quality looking sign, then foam letters, signs and logos are one of your best options. Dimensional foam signs, logos and lettering are a great way to enhance the character and depth of your message and to build recognition to your brand. Learn more about fabricating foam letters on our website page #letters #logo #logos #sign #signs #foam #foamletters #foamsigns #foamlogos #stageletters #customletters #dimensionalletters #foamcutting #foamcuttingservices #cnc #cnccutting #styrofoam #styrofoamletters #coating #hardcoating

Our customer, TODEC requested that we fabricate a custom large Monarch Butterfly prop and some large letters for their organization big event. They wanted the prop to be 2D resembling a 3D shape. We had a plan to create the butterfly with flat wings and a vinyl print, with slightly rounded body. The piece would then be mounted to a base so people can stand around it. The letters would also have a base with writing message on it as well as 2 smaller butterfly props decor on top of the letters. We received illustrator art files from the customer. We created a CAD file mockup rendering then got to work. We used our CNC hot wire foam cutters to cut the TODEC letters, 1 large butterfly prop core and 2 small ones. The right and left wings of the prop were hot wired cut separately due to its size, then glued together. We also cut a banner and glued it on top. The butterfly prop was covered in black epoxy hard coat and paintd black as well. We then hot wired a 2" thick EPS wings nest cavity template and patched all thin areas with dry mud to add strength to it. We painted the nest black and glued it onto the solid wing core, then painted the wing cavities with 5 custom orange colors. The whole large butterfly prop was fabricated at at 92.5" x 96.25" x 25" plus a base to be able to be free standing, so the total height was over 8ft. The letters were fabricated at 3ft tall with the same process as the butterfly - hot wired cut, epoxy hard coated, then painted blue, with the "O" and the "C" cut at the top to be able to glue and nest the small butterfly props. A base was cut, hot wiring the letters cavities "PROTECT DEFEND ENGAGE" then painted brown. A top banner was created in the same process - hot wired with a template nest and cavities painted yellow, orange and blue, then all glued onto the top of the prop. The 2 small butterfly props cores were cut on the hot wire CNC foam cutter. We printed a colorful vinyl print design, glued it onto the prop cores, then glued them to their already made cavity on top of the "o" and "C" free standing painted letters We flattened the vinyl with a spatula to eliminate any possible air bubbles, so that it'll be nice and smooth Here is the large butterfly constructed with the banner and the base, all hard coated and painted. The custom oversize foam prop butterfly and letters are all done. Lots of precision cutting, template techniques, accurate painting and paying attention to details... and the TODEC project is all packed on the trailer where we delivered it all in Perris, CA for the event. #foam #letters #sign #signs #prop #props #customprops #largeprops #oversizeprops #foamcutting #foamcuttingservices #cnc #cnccutting #cncmachining #machining #decor #decoration #event #eventdecor #hotwirecutting #banner

Our customer, Cache Creek Casino Resort wanted us to fabricate 10-12ft foam logo letters to float in their pool for an event. They wanted us to deliver it from our SUnnyvale, CA faclity to their location in Brooks city. But crossing the bridges on the way and delivering such a large project was an obsticle and a challenge. So what did we do? The customer provided us with their logo photo as well as instructions on how they visioned it floating in the pool We then provided rendering for the customeer to aprove cutting Using our CNC hot wire foam cutter we cut the logo shape out of 1.5lbs EPS foam. Since the logo diameter was at 11ft and the foam block being at 4ft, we had to make it in 2 halves, each half in 3 section pieces, all glued togehter. To eliminate the glue line sims as much as possible, we patched it using drywall mud, then sand it. We cut the letters then took them out to create the hooow letters effect We then painted the logo with primer and a black and white paint from the inside of the logo. Next step was to paint the logo gold. We used a specialty gols paint with Ochre base. We brushed multiple layers of the gold to make it look shiny and smooth, yet old-like uneven texture for a more natural effect. We had to fabricate it folding for easier transport as at 11ft it was too big to load on the truck or cross the brisge on the way to the customer. We crated the logo as 2 halves and placed hinges at the back so that it will be able to fold, then can be unfoald at the pool. We secured the hinges with wood pieces. Last phase was to put eye hooks on each side of the logo where a nylon cord goes through then toed to the esges of each side of the pool so that it does not float away. Here is the final logo in Cache Creek Pool - Looking great out there For more information and to see some more of our fabrications visit our Instagram page #foam #CNC #logo #flaoting #pool #letters #Cachecreek #foamcutting #cnccutting #floatingpoolletters #flaotinglogo #poollogo #largelogo #floatingpoollogo #EPS #gold #cnchotwirefoamcutting #cncfoamcutting #sign #signs #display #exhibit #casino #resort #event #events

CNC machining is a process that utilizes computer numerical control (CNC) technology. It is used to cut foam and other materials into complex 3D shapes. CNC Machining is used in a wide range of industries such as aerospace, automotive and medical industries to manufacture custom parts and components. Its adoption is highly associated with its high accuracy rate and provides a great solution for cutting and shaping foam materials. It is also an efficient way of making intricate shapes and designs. The following article will help you understand the different types of foam material that can be used when CNC machining. It also tackles the benefits of using CNC machining and the different techniques used to make complex shapes. What is CNC Machining Foam machining is a process used to create parts or products from foam. It's a versatile and efficient way to create products that are custom-made to your specifications. Foam cutting can be used to create a wide variety of products, including aircraft parts, medical implants, vehicle parts and many more. Foam machining is a fast and cost-effective way to create high-quality custom-made products that you can trust. Techniques Used In CNC Machining Foam CNC machining is one of the most exciting technologies available today. It's quickly becoming a popular choice for businesses and consumers alike. It is a process that uses CNC Routers and other machinery to create parts from foam. This technology is incredibly versatile - it can be used to create products from a wide range of materials, including plastics, wood, composites, and even metal. What's more, CNC machining is fast and easy to use, enabeling the creation of complex parts using just a few simple tools. Types Of Foam Material For Foam CNC Machining When it comes to foam CNC machining, there are a few different types of materials that can be used. Each type has its own benefits and drawbacks, which is why it's important to choose the right type of foam for your project. The first type of foam that can be used is polyurethane foam. This type of foam is popular because it's easy to work with and it has a high degree of flexibility. This makes it great for creating parts that need to be bent or curved. polyurethane foam also has a high level of resilience, which means it can absorb a lot of damage. The second type of foam that can be used for foam CNC machining is polyetherimide foam. This type of foam is similar to polyurethane foam in terms of its properties, but it has one major advantage - it's less prone to infections. This is due to the fact that polyetherimide foam is made up of countless tiny cells that are resistant to bacteria and fungi. The third type of foam that can be used for foam CNC machining is EPDM rubber foam. EPDM rubber foam is a hybrid type of foam that combines the properties of polyurethane and polyetherimide foams. This makes it a great option for parts that need to be flexible but also resistant to damage. EPDM rubber foam also has a high level of impact resistance, which means it can handle a lot of stress without breaking down. So whether you're looking for a flexible type of foam or one that's resistant to damage, there are a few different options available to you. It's important to choose the right type of foam for your project so you can get the results you're looking for. Benefits Of Using CNC Machining Foam CNC machining is a great way to create custom parts quickly and easily. Here are some benefits of using Foam CNC Machining technology; 1. It is Versatile With this technology, you can easily create parts from a variety of materials, including plastics, composites, wood and metals. Foam CNC machining is also a very versatile technology - you can use it for a variety of applications, including manufacturing, engineering, and construction. 2. It is Eco-friendly In addition, foam CNC machining is environmentally friendly - it doesn't require any oil or gas, and it doesn't produce any waste. So if you're looking for a technology that's environmentally friendly and versatile, foam CNC machining is a great option. 3. High Accuracy The technology operates autonomously without human intervention. This eradicates the chances of human errors that may occur in the production line. This makes it a high-accuracy technology to use. 4. It Is Efficient The technology is automated and has the capability to run for 24 hours non-stop. This is unlike human labour which requires regular breaks and resting time. It is also precise in cutting – meaning that it has less waste. This makes it an ideal technology that promotes efficient and fast production to meet the demand ratio. Conclusion CNC machining is a fast and easy way to create custom parts quickly and easily. With this technology, you can easily create parts from a variety of materials, including plastics, wood, composites, and metals. Foam CNC machining is also a very versatile technology - you can use it for a variety of applications, including manufacturing, engineering, and construction. And if you're looking for a technology that's environmentally friendly, cost-effective, and versatile, foam CNC machining is the perfect option for you.

We created this foam prop for a large holiday celebrations of Central Church, NV, December 24th 2022. The plane prop is 18ft wing to wing and 13ft from front to tail. We machined it from 2lbs EPS foam. First, we broken up the design into sections: - 2 wings - Fuselage (made in 3 sections) - Tail (3 sections for the horizontal tail / 1 section for the vertical tail) - 2 engines machined separately - 2 propellors machined separately Due to the size of each wing, we could not just glue the wings to the fuselage - it will not hold and would not be safe, so we had to come up with a more creative way to hold them all together We placed 2 hollow tubes in each wing, about 1.5" in diameter. We embedded (2) of 1.5" rods into the fuselage that connected into the pipes inside the wings. That was a great solution also for transportation - The propellors, the wings and the fuselage were all removable, so it did not take up so much space. We painted all parts of the plane a grey acrylic paint color, then printed decals and stickers using our wide format vinyl printer, to glue onto the plane. All disassebled parts were put inside the truck heading from Sunnyvale California to Henderson Nevada for the big Christmas event at Central Church. They did a great job assembling all parts on site and hunging it from the ceiling, with the plane being able to be lowered onto the stage and lifted up as needed. The plave weighed about 100lbs. #props #planes #Christmas #church #decor #decorations #foamprops #foamdecor #stage #stagedecor #christmasevent #planeprop #Centralchurche #holidaycelebration #vinyl #decals #vinylprint #vinylprinter #wideformatprinter

We are having lots of fun fabricating this statue. Basically, a foam replica of Venus de Milo, the famous statue posted at The Louvre, Paris, but with a twist (more of a nose twist). We call it Venus De Squidward Remember episode 2 when Squidward was teaching art to SpongeBob? Squidward got all jealous at the beautiful sculpture SpongeBob made and put his tentacle nose on it. Well, we fabricated this statue at our "mini Louvre" shop. We started out by scaling and splitting the Venus De Milo model into 5 pieces to be able to nest into our 4'x4' block of 1.5lbs EPS foam, then machined the 5 pieces on our CNC router milling machine. We then glued up all the pieces together and hand shaped to get them ready for coating. Then came the fun part - We broke off the original nose and hand shaped a Squidward tentacle shaped nose. We glued and attached the new "improved" SpongeBob style nose to the statue. Next, we placed 2 thin coats of Durham's hard putty, to be used as the hard coating base. This is a great material to be used as a hard coat but also enabled us to give the statue the old-look texture and style. We sanded it a bit then applied 2 additional thick coats of the material. That also took care of filling in any remaining gaps and holes in the texture. Et Viola! Venus De Squidward is almost done. The real Venus De Milo exhibit at The Louvre is out here - can you spot it? Now we need to do another round of sanding to shape as well as one last coat of the putty to seal up any remaining blemishes. We will seal the deal with sponging on a translucent turquoise paint, to give the statue a more natural weathered ocean-like aesthetic look. I think SpongeBob and Squidward would both approve #SpongeBob #Squidward #sculpture #statue #prop #props #EPS #Styrofoam #CNC #machining #milling #routing #Venusdemilo #TheLouvre #coating #hardcoating #sealer #putty #TVcharacters #hardcoat

We were recently approached by Kav Sports to create a 4ft foam hockey helmet for a trade show they are participating in The customer provided us a smaller 3D printed version of the helmet prototype. They asked us to create a 3D machined helmet that can be broken into pieces then put back together. We started out by CNC machining the helmet shape pieces on our CNC router, using 2lbs EPS foam, then sanded all pieces thoroughly. We then coated it with first prime coat of epoxy and sanded again Then came the DryDex spackle - It's a paste we use to eliminate cracks, making the surface smoother and ready for the next coat. And of course - sanded again... Then came the top epoxy coating Then came black painting, sanding, then the finish paint The last phase was to create the stand and the base. We also laser cut our logo and attached it onto the stand Hard to believe this helmet is actually made of foam... Now working on being able to take the parts apart and assembling it all back again. #helmet #helmets #props #display #displays #exhibit #exhibits #prototype #prototypes #prototyping #cnc #cncmachining #machining #foam #foammachining #foamcutting #foamcuttingservices #foammachiningservices #foamexhibit #epoxy #coating #hardcoating #epoxycoating

We had quite a few large scale projects, and we love creating those, so you can understand our excitement when a customer asked us to produce a 72" long punchout knockout prop for their tool company We machined it on our CNC router, using 3lbs EPS - the highest density of Styrofoam to add strength and durability. We machined each part of the entire tool separately, then glued all parts together We used speckle drywall mud paste to cover any cracks in the foam and eliminate any imperfections. Then sanded again to achieve a smoother finish prior to applying the hard coat We then placed Epoxy hard coat on top, to make it stronger and more durable. The company name was engraved into the foam Last phase - We painted it with black and green paint, then spray painted the logo and "made in USA" with gold paint onto the tool, using templates #foam #tool #tools #exhibits #cnc #machining #display #decor #decoration #foamcutting #foammachining #foamcuttingservices #cncmachining #router #milling #logo #prop #props #foamprops #oversizeprops #largedcaleprops

How fun is our job... Cannot get any better, following a request from an event planner customer asking us to fabricate a 2.5ft Converse high-top shoe prop display. We started out with a 3D CAD file of the shoe which we uploaded into the computer connected to our CNC router, so that the machine will be able to cut the desired shape. We made sure our CNC router will machine several shoes, just as a backup - all machined from 3lbs EPS foam. Here is our CNC router where all this machining magic took place Then lots of sanding took place Next stop: Adding Epoxy hard coat which we applied by spraying and brushing 3 coats. Then, some more sanding took place. Sensitive spots such as sims, tiny holes/cracks were filled with DryDex Spackling material then you guessed it - sanding again... We then primed the foam shoe with the basic orange paint, prior to the actual painting. Painting then took place - The shoe was painted orange and white, the nits were painted silver to resemble nickel metal, and black paint was gently added to the sole. As soon as the paint was dry, we printed the logo design using our vinyl printer, on adhesive backing paper which we glued onto the shoe. Then came the tricky part - adding the shoe laces. We used a fancy fabric for the laces. Francisco, our artist of many talents glued the laces into the nits while tightening and shrinking them inside the holes, making it appear as real laces running through the shoe Et Voila! Here is the final shoe prop to serve as a display exhibit by the customer for branding their product and company at a trade show Now, can you tell it's made of foam? I sure can't, and I made it... Next post coming - Will show you how we made a 6ft long foam knockout tool prop... #props #shoes #display #displays #exhibit #exhibits #cnc #cncmachining #machining #foam #foammachining #foamcutting #foamcuttingservices #foammachiningservices #foamexhibit #router #routing #cad #cadfile #3d #Converse #Converseshoes #shoesdisplay