Very High Density Foam for Fine Detail Carving

[tallen84]

Does anyone have small (approx 12" x 12" x 0.5") quantities available of some very high density precision HDU foams? Ideally something like General Plastic's FR-4625.

I am trying to machine parts of a model that require very fine detail. I have tried 18lb HDU but its too coarse, also tried Delrin plastic but keep breaking the fine bits since the plastic is too hard.

I am machining pieces using bits as small as 0.03". I get decent results on the delrin but I think since i am using vcarve pro 8.5 instead of more advanced CAM software the 3D finishing tool path occasionally likes to bury the bit aggressively causing them to break.

Thank you.

[a.werby]

Do you still need this stuff? I've had good luck with the "precision board" made by Coastal Industries http://precisionboard.com/. They'll send out free samples for you to try, which as I recall were about a half-inch thick.

Andrew Werby
computersculpture.com

[tallen84]

Andrew, Thank you for the reply. I am familiar with precision board and I can recommend it for general use. I was working on something that required an incredible amount of detail so I ended up using 31# Duna corafoam with good results.

[EricSchimel]

Andrew, Thank you for the reply. I am familiar with precision board and I can recommend it for general use. I was working on something that required an incredible amount of detail so I ended up using 31# Duna corafoam with good results.

Is this something you could 3d print instead?

[tallen84]

Some parts of it may have been better to 3D print while others were too large to reasonably do so. Since this was a personal project I could not warrant subcontracting the printing so I used the shopbot for all of it.

[pro70z28]

Do yo have any photos of the end results?

[bleeth]

FYI Precision Board does have up to 75lb available. That is very dense.
It is approved as core material under FRP in boats for mounting cleats through.
Most sign guys consider the 30 lb the top they ever need to go and generally use 18.
And also, (unless it is confidential) like to see some pics as well.

[tallen84]

I have not used the precision board with that high of a density but will see if I can get a sample of it for next time. At the lower densities I tend to prefer Duna corafoam products over precision board, I find it seems finer than competitor's foams at the same density, is easier to finish smooth, less gritty, and is more easily available locally (Duna USA is somewhat nearby).

As for the project, it is a name sign I am making to go over my daughter's bed. This one is modeled after the Disney World castle with a few tweaks (I created one previously for my son that was modeled after the Pixar Cars logo). It is currently about 90% complete, I am finishing the internal LED lighting and still needs a few finishing touches.

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[willnewton]

As for the project, it is a name sign I am making to go over my daughter's bed.

I was expecting some version of a sign, featuring a name. You know, just “regular old sign” type stuff.

THAT is not just “a name sign”! Very cool work!

[Brady Watson]

Wow! Very nice! Somebody loves his little girl!

-B

[tallen84]

Thank you! Every princess needs her castle :)

Several years ago I also made a custom sign for my son (see attached) so I had to come up with a unique one for my daughter as well. My son's sign didn't have as much detail, however, it took a huge amount of finishing to get metal like chrome finish from HDU foam.


Just remember, anything worth doing, is worth over doing.


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[Brady Watson]

Very cool! I see that going to college with him...and/or his own garage.

-B

[tallen84]

Thought you might be interested, attached are some finished / installed photos.

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[Brady Watson]

Wow - really stunning! A labor of love for sure. Thanks for posting

-B

[Chuck Keysor]

WOW!!!!!!!!!!!! And then you turned on the lights!!!!!!!!!!!! WOW!!!!!!!!!!!!!!!!!! Great work! Chuck

[bleeth]

Really wonderful. She's got a great dad.
I also prefer Duna on a pound for pound comparison but their distribution network is not as wide as Coastal.
I don't think they make the heavier density either.