MACHINES AND CAPABILITIES

CNC Routing Machine with Oscillating Knife

CNC router (Computer Numerical Control) is a computer-controlled cutting machine allowing for precise 3 & 5 axis cutting. This fully adjustable machine which combines cutting edge technology with full flexibility and control, allowing us to achieve a varying depth of cut and complete 3D shapes to a very high accuracy, making this an ideal machine for the effective production of highly technical parts.

CNC Horizontal Contour Cutting Machine

Foam Converting machine especially suitable for technical parts which require extreme accuracies. At the heart of our factory is our Horizontal Contour Cutting Machine allowing us to fully optimise our production, we offer comprehensive ability to create bespoke, one-off technical foam shapes for a range of applications.

Vertical and Horizontal Cutting

Using either saw blades or knives to suit most cutting techniques our large adjustable sliding table cutting machines allow accurate cutting of large blocks for safe and seem-less foam conversion of all types.

CNC Twin Router with Copy Tools

The two carriages seen here each have a single spindle but they could have 2 or even 3 spindles or knife tools. The two heads can work either together for double the production or separately for fast switching between different tools. This machine also has an automatic tool change system to allow complex jobs to be run with no operator involvement, suitable for one-off, small batch production as well as high volume and high productivity applications.

Thermo-Forming

Thermoforming is where a foam sheet is heated to a pliable forming temperature, formed to a specific shape in a mould, and trimmed to create a usable product. The sheet is heated in an oven to a high-enough temperature that permits it to be stretched into or onto a mould and cooled to a finished shape. Our In-depth knowledge and experience of thermo-forming foam has been built up, year on year for decades. We produce critically relied upon products for a number of customers. We are always willing to develop new designs and challenge our manufacturing processes.

Die Cutting

Using a specific bladed die cutting tool, which is made using laser precision, we are able to press stamp exact shapes from foam sheets of varying thicknesses usually to an agreed tolerance and on a fully adjustable press machine.
Accuracy: A sharpened die, with the correct amount of clearance between the press and die, will produce a part that holds close dimensional tolerances in relationship to the part’s edges.
Appearance: Since the part is blanked in one operation, the finish edges of the part produces a uniform appearance as opposed to varying degrees of burnishing from multiple operations.

2D & 3D toolpath software

We have invested in the latest cutting edge 2D & 3D software packages which are compatible with our CNC machines allowing us to generate technical 2D & 3D design drawings, models and cutting programs.

Sheet laminating machine

During the material preparation process it is often necessary to produce a sheet with a greater workable thickness, especially for our CNC routers. This is where our automated sheet laminating machines are used. Material is bonded together without the need for adhesive. This creates a very strong and consistent bond between each layer of material.

3D Machining

Foam Engineers has developed an advanced way of successfully 3D machining very technical shapes using our bespoke 3D machines creating an ultimate and unrivaled 3D foam product. This allows us to engineer precise and complex products for specific applications.