5 Reasons for Using Foam

July 17th, 2017

More and more custom fabricators are turning to foam as the material of choice for a wide range of production processes as well as finished products. While not a traditional material like wood, clay, or stone, foam brings with it a number of modern conveniences and qualities which makes it an excellent medium for fabricators in numerous industries and applications:

1. Foam is affordable:

Compared to virtually every other material, a block of foam is dirt cheap. And yet, a good EPS foam will hold a high quality of detail and produce a stunning end project. Dramatically lowered materials costs across the board can substantially increase profit margins on all projects. Moreover, projects which would be prohibitively expensive using traditional materials, particularly when approaching large-scale or one off pieces, become not only feasible, but also highly lucrative. 

2. Foam is fast:

Foam blocks are easily available in a range of sizes. This allows fabricators to create large-scale projects with often a single block. Using 3D CNC foam carving equipment, such as the FROGMill™ 4 axis CNC router, these large blocks are carved automatically, dramatically reducing manual labor and resources while maximizing production quality and capabilities. Faster turnaround both increases total throughput (and profits) and expands product ranges and market reach (and profits).

3. Foam is light:

Due to its light weight, foam makes managing pieces and parts much easier. From production, to transport, to installation, foam is simple to handle and can result in a difference of thousands of pounds of material. Because of this, foam can be used to tackle projects which would be impossible using traditional materials while also making more routine projects much easier to complete. Greater flexibility, reduced handling times, and increased production speeds all contribute to improved bottom lines.

4. Foam is durable:

Thanks to special protective coatings that are applied to the foam using plural component spray equipment, foam is virtually indestructible. Able to withstand harsh environmental pressures, foam can last for generations. In fact, compared to many traditional mediums, foam is a better long-term material as it will not rust, pit, rot or wear down.  Even if the foam is being used for molds, plugs, or prototypes, rather than the finished piece, foam is sturdy, and producers can expect to get numerous pulls off of a single form. 

5. Foam is flexible:

A host of finishing products and techniques are available that transform the look of foam. Foam can be made to resemble bronze, wood, stone and a multitude of other materials. Not only does this allow for a great deal of flexibility in the creative process, it also contributes to the economical aspect of foam. After all, a sixty foot foam sculpture that looks like it is cast in bronze is a lot more affordable than an actual sixty foot bronze sculpture! 

From concrete molds to foam sculptures to stage props to rapid prototyping and beyond, foam brings some serious production advantages to the custom fabrication process.  When used in conjunction with the FROG3D® System, producers can tap into the full range of benefits that comes with automated foam carving and cutting.

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