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Discussion Starter #1
Honest John commented on the foam he uses a while back, but I can't really find it. So, what foam brands do people use and recommend? Also, which would you never use again?

And, what are other alternatives to foam, ply or real wood for 3D carving?

I need to machine a 3D model at a size that makes real wood not as practical.

Steve.
 

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Oliver (Prof. Henry)
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I have used HDU Precision Foam which is available is cut sheet sizes from InterStateHDU. The 15# board I used is available in .75, 1, 1.5, and 2 inch thickness and the following sizes in inches: 12 x 12, 12 x 24, 12 x 36, 12 x 48, 24 x 24, 24 36 and 24 x 48. They are packaged well to protect during shipping. I like it and will definitely use it again. I cuts easily with crisp edges.
 
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Steve,

I was talking about Corafoam. Alpine Sign in Lansing carries it now. Ask for Rob. They do deliver cheaper than you can drive and go get it.

How big a piece you need?
 

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Discussion Starter #4
John - for two of them I need 42" square and another 18" square

Have you tried the foam store up on Hall Road? Years since I was there.

Steve.
 

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I got some 48 x 48 pieces of 3/4 and 1" Corafoam here. Didn't even know there was a foam place by me. Alpine will deliver a full sheet cut however you want it for, I believe, around $15.
 

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I don't know the brand name but get it from a sign supplier, 20 and 30 lb , 4x8 sheets in 1" and 2" thickness. carves like butter
 

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Honest John,
I know very little about the CNC, just enough to get me into trouble. Question, do use the CNC To cut signs and such in the foam? Are you using the foam in some other way. What type or kind of bit do you use when cutting foam pieces?

Thanks, Tagwatts
 

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Frank,

You can use foam to cut or carve most anything. I"m partial to Corafoam. It comes in sheets up to 4 inches thick. It doesn't bend, warp, rot, or anything else. Using 100% acrylic paint you can prime it and paint it - hang it outside , and you shouldn't have to touch it for 8 to 10 years or better. Most of your newer "carved" business signs are made of this type of material- not wood. You can usually cut everything in one pass. No roughing pass is usually needed. Plus, there's virtually no waste, since there are no knots or imperfections. I've pocket cut letters less than a 1/16" with no chipping. I just use my regular bits. They last forever cutting this stuff.

Send this guy an email and he'll send you a free sample - [email protected]
 

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Discussion Starter #9

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Frank,

You can use foam to cut or carve most anything. ... Most of your newer "carved" business signs are made of this type of material- not wood. You can usually cut everything in one pass. No roughing pass is usually needed. Plus, there's virtually no waste, since there are no knots or imperfections. I've pocket cut letters less than a 1/16" with no chipping. I just use my regular bits. They last forever cutting this stuff.
Definitely what John says.

Wide signs though maybe 3'+ either direction may need internal support
of MDO ply or a metal frame within thats usually pocketed behind or "encapsulated"
for a double sider. No pun intended, the signs will float too.

My "BEEF" with HDU is.... the damn dust is gritty and clings to me cup of coffee.
Piss someone off and sprinkle it on their sweaty neck.... :wink:

Paint with Fuji Mini-Mite 4/5 (Q costlier and optional) for a nice finish
 

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Oliver (Prof. Henry)
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Seems like a good source, I need to get some shipping costs. They would make it easy to price a job.

Steve.
Shipping on my two orders was around $20 - $30 so it is a good idea to check with them first. With a small order, the shipping can equal the cost of the material. Two pieces of 1" thick 24" x 24" 15# HDU cost me $107 including shipping.
 

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Discussion Starter #13
Shipping on my two orders was around $20 - $30 so it is a good idea to check with them first. With a small order, the shipping can equal the cost of the material. Two pieces of 1" thick 24" x 24" 15# HDU cost me $107 including shipping.
Yeah, I tried the checkout for shipping cost and at least the first 3 are included in the base shipping price. Actually reasonable if you have the work sized to minimize waste.
-=-=-=-=-=

"gritty and clings to me cup of coffee." - that could be a problem in the morning.


Steve.
 

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Steve,
Email Brad at Duna and get a sample sent to you and see how you like it. I bought a bunch from Pioneer in Pittsburgh and the shipping was $175. Now Alpine has it and they run around our area once or twice a week. Last time I talked to Rob shipping to Rochester was something like $12 or $15. It's some good stuff.
 

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Discussion Starter #15
Send this guy an email and he'll send you a free sample - [email protected]
John - I went to Duna Group and found the following;

CORAFOAM® F Closed-cell polyisocyanurate foam for market of artificial flowers. Density between 1,8 and 2 Lbs/ft3. The foam does not absorb water and is available in different colours, in blocks or little blocks. CORAFOAM® F 15 CORAFOAM® F 20
CORAFOAM® F 21 CORAFOAM® F 22 CORAFOAM® F 23

CORAFOAM® R
A new family of foam particularly developed for carving industry, especially set and stage designing, scenography. CORAFOAM® R 40 CORAFOAM® R 60

CORAFOAM® P
Polyisocyanurate for cryogenic insulation. Density between 2 and 3 Lbs/ft3. Sold in blocks of 3 ft, mainly employed to obtain supports and pipes for piping lines and tanks. CORAFOAM® P 20 CORAFOAM® P 25 CORAFOAM® P 30

It isn't clear on the Duna site if the two digit number is the density or not.

Which flavor are you using?

Steve.
 

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Steve,

Plain old 15" density - made before they even started promoting it to the sign and carving industry. Rob at Alpine or Brad right at Duna can give more info. I know they now promote the use for signs and carving, since it has become so popular for this use. This stuff wasn't developed for that - - it is used mainly in the petro chemical industry. There's a plant in Ludington that just turns this stuff out.
 

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The product for signs is Corafoam U 150. That is 15lb cu/ft.

I hope you get better service from Duna than I did. I called and requested to speak to someone about sign foam and was given the cell number to their outside sales lady.
I called with no answer 3 times and left a detailed message concerning my product needs. Never a single call back.

I travel to the Houston area from time to time so I will pop in on them and speak in person.


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$400 for 2"

Under $200 for 1"

I believe about 150-175 for 3/4 inch

With a $12 delivery charge for smaller orders.
 
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