Router & Laser Cutting Specialists

EPS FOAM - Expanded Polystyrene Foam

Introducing some of our work in creating shapes from various foam products.

EPS and higher density foams offer a cheap, lightweight base for shapes and signs. It is very popular in the modelling industry, and in theatrical and movie, film stage props. It can be easily hand carved, with a little expertise, for creating shapes such as false rocks, hillsides, structural panels with features such as stone, or brickwork. It was used extensively in Peter Jacksons Lord Of The Rings, along with spray foam (in a pressurised can), and expert artists to recreate the authentic look.

Our foam cutting machine can aid in production of fairly accurate custom shaping, where repetivity of round, or linear curves is required. The cnc can create miniture terrain models, and if you have the correct contour data, it can even reproduce actual geographical earth features like Mt Cook below. Ideal for displays, or film work.

On the left is a 3D Terrain Model from geographic elevation and contour data. This is Mt Cook, NZ, cut from a single piece of 1 meter square PVC foam, and painted by artist.

A picture showing the high density foam before painting.

A zoom in shot of the contour resolution in the foam.

Here is a detailed foam miniture ring from the "Stargate" sci-fi TV series.

Zoom in of the details.

Part of a sign cut from high density foam, this is 40mm thick. High density foam is available in many sizes up to 100mm. This material is available in sheet form measuring about 640mm, and the length is about 2500mm. So, any signage or shapes must fit inside these dimensions, or be cut from multiple pieces. High density foam has a very smooth finish, but must be handled with care as it can be dented easily. This must be painted with water based paints, as any other type will simply begin to melt the foam. We can also cut a different type of foam suitable for enamel and lacqer based paints.

Column bases for Faux Roman Columns. These are usually fitted around a 100x100mm support post (they are made in two halfs, with a recess for the post in the middle). A plasterer finishes them to look and feel like the real thing. Our specialised cutting machine has a standard set of profiles, but custom profiles are also possible. We can cut any profiled disc up to 2 meters diameter, and 1.5 meters tall. More complex shapes can be stacked. These can also be used as a base for making a more permanent fiberglass moulding.

We can also cut linear sections of any profile for custom door or window mouldings. As an example, the classic gothic arch in detail. Will provide pictures when I can.

Some more polystryene rings cut with an external profile.

And finally showing some 3D cutting into foam. This can be used as a lightweight ceiling feature, once painted. but simply serves as another example of 3D cutting.

Thanks for visiting our web site, and don't forget to check out our other pages showing examples of our work.

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