3D Foam Parts (CNC Machined)

We pride ourselves on designing and manufacturing 3D Foam Parts which may involve a combination of fabrication, processes/machining and indeed skilled hand finishing to achieve the desired shape. As engineers with huge experience we tend to know what can be achieved and how to convert foam materials into various shapes and 3D geometry which are increasingly becoming needed and demanded. Design and products have moved on along with design flair and creativity plus technical performance which typically imposes 3D foam components and parts via sophisticated software packages.

Using a compliment of CAD (Computer Aided Design), CNC (Computer Numerically Controlled) and CAM (Computer Aided Manufacture) software suites, Kewell Converters Ltd. Can work with and create 3D design models of any foam object required by our clients to strict specification, simple or complex. Alternatively, we can make use of existing drawings or sketches supplied to us or work of original parts/items/dummies/samples and reverse engineer to finalise and approve 3D or 2D foam products and parts.

Using top-of-the-range CNC Routing and Pure High Pressure CNC Water-Jet technology to set up the machine with unparalleled accuracy, these 3D designs are converted into the finished product - from prototype or one-off object to a batch run of thousands.

Mastercam CADCAM software gives us the best possible foundation for fast and efficient router cutting and milling/machining of foam and composite materials. From general purpose methods such as optimized pocketing to highly specialized toolpaths like 5-axis trimming. Mastercam ensures that were’ ready for any job. Mastercam delivers:

  • Full 3D CAD modelling.
  • Easy pocketing, contouring and drilling.
  • Built-in nesting, engraving, aggregate tools and much more.
  • Streamlined multi-axis cutting, trimming, and drilling.
  • Optimized motion boosts tool life and decreases cutting time.
  • Specialized options for focused projects.

Mastercam Router can grow with your business. Start with what you need, and upgrade to new machining techniques as your needs grow.

Having the best software is only one ingredient for success alongside our years of experience, skill and technical knowledge we can design and manufacture the best 3D Foam products. High production yields can be crucial to a job costing and ensure the most economical manufacturing methodology and supply. Mastercam includes essential nesting capabilities for parts and toolpaths that assure optimal material usage for the highest possible yields giving best value for money and fast turnaround/short lead times of high quality. 3D foam items we have helped design and manufactured can be seen here and are in more detail here.

Request a quote or order your free sample today.