I knew that when I finished my birds, I would want a way to safely ship them. So having a CNC my thoughts naturally went to designing custom packaging, and foam seemed like a great shipping and machining material. I purchased a specialized Datron foam cutting endmill for the task. After learning ho…

[image] TMToronto: I have ordered a variety of PE and PU foam samples, and will continue to fine tune the machining. I want to find the best foam Have you tried foam insulation panels from the big box stores? I use that a lot for shipping stuff.

Thank you for the suggestion - I appreciate it :grinning: I have not for this application. My initial (inexperienced :smile:) thoughts were: *I need 1.5" thick material, which here in Canada starts to get expensive compared to other material *I want something softer so that 1) there is no risk of…

Sourcing is always a challenge, but I enjoy the quest :grinning: There are a few foam suppliers in the GTA that I can drive to, so that saves on shipping (which is becoming less ideal given the cost of gas and 400 series highway traffic!). One even will let me purchase, and if upon pickup it does n…

I have had good success using “Kaizen” foam; it’s layered/bonded and can be had at The Depot. Ordered online and shipped to my closest store. [IMG_4428] 2x4 Sheets, ~$30 for 3/4" thick and ~$40 for 2" 3/4": https://www.homedepot.com/p/FASTCAP-Black-Kaizen-Foam-24-in-x-48-in-x-20-mm-FC-KF20-2X4-…

Thank you for sharing the photo and suggestion. The plank foam sample I found (in my basement :smile:) I believe is a similar material to the branded Kaizen foam. It worked well in my very first trial, but would be too expensive as a final solution if sourced similarly.

Thank you for the suggestions and insights. At this point in my retirement, and still being new to CNC machining, everything I am designing, building, and machining is for gaining personal experience and pleasure with this new hobby. That includes having the challenge of figuring out a machined foa…

[image] TMToronto: What type of products do you ship using the insulation panels? Just about everything from metal projects (CNC plasma created) to wooden projects (OF created) and even tech stuff. I wrap the piece in paper first (packing paper sheets from Home Depot) and then lay it into the…

Thank you for the additional information. Seems like a 3 layer solution deserves a thorough cost comparison to the 2 layer fully contoured route - time, end mill wear, ‘mess’, etc… aside. My foam samples are expected tomorrow, so I will see what new insights the weekend experiments provide. I need …

I am providing an update for those following. I received the foam samples from the Foam Factory ( canada.foambymail.com ) and completed a quick machinability test. I uploaded the video to my YouTube channel TMDesign - here is a direct link to the video: [CNC machinability of 5 different foams…

That is a magnificent Eames house bird. Do you have a post describing the process?

Custom foam packaging for my Eames House Bird inspired 3D carve - update with new foam

Gallery

TMToronto August 5, 2023, 10:43pm 14

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Custom foam packaging for my Eames House Bird inspired 3D carve - update with new foam

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