Knowing what type of foam is suitable for your applications can be challenging. Both high-density foam and polyurethane high-density foam have distinct advantages, and you should explore each one to pick the best option.
Below, you’ll learn more about high-density and polyurethane foams, their common uses and how CNC machining services can help you achieve a high-quality, reliable final product.
Here’s a quick overview of what each foam is so you can better understand their applications:
High-density foam is an industrial-grade foam of medium quality made from a polyurethane blend. Low-quality, high-density foam tends to off-gas, meaning it can give off a chemical in the form of gas. You should look into higher-quality, high-density foam if you need to work in a space with clean air.
Some applications of high-density foam include chair cushions, sofas, boats, camping pads and bay windows, making it most popular within the furniture manufacturing industry. High-density foam can last around four years but has the potential to hold up longer with the proper care.
Because it’s so firm, this foam isn’t often used to create entire products or pieces. High-density foam is ideal for product foundations or as extra support.
Polyurethane foam is a high-density foam and is a blanket term for foam made from polyol and diisocyanate. Different polyurethane foams include high-density, high-resilence, rebond, lux and memory foam. This type of foam is ideal for packaging, shipping, arts and crafts, costumes, and other recreational applications.
The main difference between these foams is their density. Thicker high-density polyurethane foam pieces tend to develop “sink” areas after some time and can’t return to their original form. However, the variation in thickness and density makes this foam ideal for situations when crucial support is necessary. Commercial-grade polyurethane foam is typically lighter, making it perfect for specialty applications.
Understanding the distinction between high-density foam and polyurethane is essential to determine what type you need for your applications. While there are many similarities between the two types of foams, polyurethane covers a broad range of foams that you can use for different applications, while high-density foam is more specific.
You can choose from different CNC machining services to achieve the ideal final product for high-density or polyurethane foam and custom-cut foam components for various applications. The two most popular CNC machining services we offer at American Micro Industries include:
CNC machine milling is the best way to obtain foam components that are accurate to the design. CNC machine milling involves placing the foam into a machine fixture where it’s fixed in place while the cutting tool works around the material to create an accurate design.
This machine utilizes various cutting tools to achieve multiple sizes for the final product. We can also equip these machines with different tools, such as drills, bores and endmills, to help create the ideal final product for your applications.
The milling process is automated with the CNC machine, which can be programmed to perform your desired actions. You can also repeat the process without worrying about accuracy, allowing you to create multiple parts that are the same.
You can also combine CNC milling with other CNC processes to help meet your needs. You can use CNC milling to create construction materials, automotive parts and other items across various industries.
One point to consider with CNC milling is that the material must be held in place while the cutting tools do the work. As a result, flimsy or oddly shaped materials can be more challenging to process.
CNC machine turning helps create cylindrical components of various sizes and dimensions. A rounded workpiece is placed within the foam on a mandrel, which rotates. As the part spins, cutting tools move as programmed, eliminating excess material until the foam becomes the desired shape. Some CNC turning machines also have a horizontal drill, which allows them to drill a hole in the center of the material.
CNC machine turning is ideal for eliminating large amounts of foam to create cylindrical parts. This process is highly precise and versatile when combined with other CNC processes, such as CNC milling, allowing you to create more complex shapes.
Computer programming helps improve accuracy and repeatability, enabling you to obtain identical parts and manufacture large amounts of the same product. The automated process keeps manual labor to a minimum, saving on costs and increasing productivity.
Depending on your needs, you may choose CNC machine milling, CNC machine turning or a combination of the two to create the best product for your applications. Remember that machine turning can only create cylindrical parts, while machine milling can create components of various sizes and shapes.
Both CNC services have benefits, including low costs, excellent accuracy and quick turnaround times. What matters is choosing the proper manufacturer that can help you create custom parts.
Custom foam components are essential to your industry, so they must be reliable, accurate and high-quality. You’ll want to find a manufacturer with state-of-the-art machinery that allows them to create seamless, quality products that suit your business’s needs. You’ll also want to choose a manufacturer that can provide quick and affordable services, allowing you to receive components promptly so you don’t risk downtime and waste money.
CNC services are complex, and without the knowledge, experience and machinery to handle the job, it can be challenging to get the results you desire. Working with a professional manufacturer ensures you get the quality you need from your foam products.
American Micro Industries’ CNC machining services can help you achieve your product goals. Our CNC machine milling and turning services are highly accurate, affordable and reliable, giving you the best quality for your budget.
We can work quickly to provide you with a high-quality component, whether you’re using high-density or polyurethane foam. We’re quality-driven and focus on each component to ensure it’s made to our customer’s specifications.
Our services apply to various industries, including aerospace, technology, defense, electronics and military. We specialize in producing hard-to-make parts that are produced and shipped from one location, allowing you to access what you need quickly without a tiresome search.
Request a free quote today, or contact us to learn more about our CNC machining services!