Foam core and EPP machining
We machine structural foam cores and expanded polypropylene for aerospace, motorsport, defence and automotive customers, up to 3.6 metres and held to 0.2 mm on the same 5-axis centres we use for master patterns.
Foam is easy to cut and hard to cut well. Thin walls, compound curvature and parts with almost nothing to clamp on to are the normal case rather than the exception, which is why we design and build our own vacuum fixtures in-house. Every toolpath is simulated before anything is cut.
What we machine
- Expanded polypropylene (EPP).
- Structural foam cores for composite sandwich panels.
- Profiled and bonded core assemblies, and kitted sets.
- Prototype one-offs through to repeat production batches.
If the material is ROHACELL, that has a page of its own. See Rohacell machining.
Specification
Common questions
Yes. We hold a range of materials in stock and are equally happy machining material you supply.
Straightforward parts usually come back the same day. Allow up to a week where the geometry or the fixturing needs more thought.
Yes. Pattern, mould tool and core can all come from us, cut on the same datums and inspected on the same system.