End Mill for foam ?

[SScnc]

Do any of you fellas know if there's an end mill that is suitable for cutting soft foam padding out to fit the profile of things ?

I mean just the outer profile of the product, then that layer can be placed on top of another layer.

I'm thinking like a small diameter EM at 30,000 RPM.

Such as below for example...

[eartaker]

When I was in high school I used to cut out foam CO2 cars on a CNC router. all I ever used were a 2 flute .25" flat and ball end mills.

[SCzEngrgGroup]

Do any of you fellas know if there's an end mill that is suitable for cutting soft foam padding out to fit the profile of things ?

I mean just the outer profile of the product, then that layer can be placed on top of another layer.

I'm thinking like a small diameter EM at 30,000 RPM.

Such as below for example...

That kind of foam would normally be cut with a knife. I'm not sure an endmill would cut it as much as it would shred it. Have you tried?

Regards,
Ray L.

[eartaker]

ahhh true, the foam i cut was the blue hard foam.

[Adam Baker]

Maybe cut it w/ a Hot Wire Cutter?

[neilw20]

Freeze it rock solid then high speed machine it.
Freeze it wet so it is solid ice, or have fun with liquid nitrogen.

[SScnc]

That kind of foam would normally be cut with a knife. I'm not sure an endmill would cut it as much as it would shred it. Have you tried?

Regards,
Ray L.

I'm not sure how a knife can be used in a cnc mill for this. You're probably right that an EM will tend to shred the foam and might want to wind up the foam around the EM, and no, I haven't tried it yet. The freezing is a creative thought and that may work. I also was thinking that maybe a 1/4" or 1/8" masonite type board can be placed on top of the foam then compress the foam and hold with clamps and plunge and cut with an EM in one pass.

I think a "hot wire" method will produce a bad looking inner surface and also be kinda hard and scratchy. But I may try it.

One other thought I had this morning is to mill a groove in a board in the shape of the outline needed then insert a steel band like that used in shipping strapping and is like spring steel. Then sharpen the edge and press cut the foam, like a "rule die" I think it's called.

I'll give it try when I locate the foam I want to use. Thanks and please post any other ideas.