Hi i know this i a long shot but fingers crossed you could help.
Dose anyone know or is capable of milling foam from a 3d cad file,to reproduce car panels a link and picture below of what i am talking about.
p.s. sorry if this message has been posted in the wrong section,theres so many sections.
However, being 3-axis (unlike the large and very expensive 5-axis CNC machines) means that the milling cutter will carve only from the top side, and sometimes the more complex shapes (eg. negative walls, very deep holes, openings at the sides and even at the bottom) will require a compound plug (two or more foam pieces milled separately and then glued together to form a multi-sided complex shape). Most (wooden) plugs for rifle stocks, shoes, large rapid prototypes etc are made this way.
The pictures below show the basic difference between the same part made with 3-axis and 5-axis CNC-milling machines:
so I take it no one knows of a machine?