Converting and Slitting 

Our fabrication begins with the conversion of raw material stock to usable nominal size sheets from either rigid foam sheet stock or larger soft foam buns. We skive to remove the outer hard skin layer and slit to split large size sheets into thinner stocks. Our horizontal bun cutter can accurately split soft polyurethane (PU) and elastomeric foams and gasket. Our Skiving saws do the same for the rigid polyethylene (PE) and crosslinked polyethylene (XLPE) up to 6 Lbs/cubic foot densities. Our skiver and buns cutters are computer controlled for precision and repeatability to attain accurate sheet thickness.  






Strip and block fabrication 

For simple geometric shape blocks, we use an arsenal of dedicated foam bandsaws for quick and accurate cutting. Able to handle large stock to cut precise dimensions or angles and bevels with our tilting saw. 



Convoluting (Egg-crate shaped foam) 

Our own custom built convoluting horizontal saw converts soft foam stock into a sheet with peaks and valleys. Convoluted foam peeks reduce the cushioning pressure of the foam material when used as a lid insert, making the storage container easier to open and close. We can adjust the thickness of the sheet to adapt the egg crate pattern to provide the appropriate cushioning as required.  



Foam Die Cutting 

Die cutting provides a fast, simple and high-volume fabrication method to cut custom shapes from sheet stock. Adapting the die and the thickness of the sheet stock, a wide variety of shapes can be achieved. Using steel ruled tools (dies) and hydraulic clicker press, foam is compression cut by driving the steel rule through the foam sheet stock. Each type of material has to be matched with its own unique rule edge to provide the best results. 

Die cutting delivers one of the lowest cost fabrication methods, with repeatable quality. We have the capability to cut an assortment of materials that complement our foams iefoamed PVC, silicon and visco-elastic sheet material. 



CNC Waterjet Cutting and CNC Routing 

CNC cutting is the most accurate fabrication for foam. We use two types of CAD/CAM/CNC machines, 5-Axis Waterjet & 3-Axis Router. Each machine has its own advantages, but both can fabricate low volume parts or variation of designs without the cost of producing steel rule tooling.   

The waterjet allows us to cut unlimited possibilities of shapes and profiles. Our waterjet cuts foam (and many other types of materials like metals, plastics, sponge, glass, stone and ceramic) with a high precision 0.005” beam of water (about the thickness of a sheet of paper) faster than the speed of sound. The 5-axis head cuts bevels and tappers up to 45° vertically, ideal for case inserts and angled profiles. The thin cutting beam can cut intricate parts with a high-density nesting, maximizing sheet usage.  

Our 3-axis router is a high speed, large bed machine capable of accommodating most sheet materials. The router is built with a 7-station tool changer and automatic measuring system. The tool changer minimizes setup and processing time to a minimum. Employing an 18HP vacuum holding, the material is held in place easily without fixture or framing. The 12HP spindle drive can handle large diameter tool bits reducing the tool paths and overall machine time. 

In the application, the router can create cavities and pockets in a wide range of shapes and depths. Tool trays, camera and instrument cases are ideal projects well suited for production. Inherent to the router cutting process, pockets and interior shapes will have a radius on inside corners created from the router bit. 



Gluing and Assembly 

This is where some of the magic happens. Achieving multi-layer, multi-material parts takes a dedicated team with focus on quality. Each part, large or small will get the same care and attention to detail.  

We employ a wide variety of gluing and techniques, each type adhesive is selected base upon material, bond and how the part gets assembled. We employ pressure sensitive adhesives (PSA), hot melt glue both as spray, roller and handgun application, heat welding for large surfaces and hot air welding for smaller areas.