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CNC router allows foam manufacturers to the usual range of 20 models of the sample in two days compared with five days to produce pieces of foam cut by hand. In addition to saving time, frees the CNC router engineers had started and to help, cut out of foam, when a large amount of samples were used. removed with the exception of one person, the burden of bearing foam and the finished piece, the router can work round the clock supervision, if necessary, from a large order. Another benefit of automation is the production of the sample, that the company, jobs, who can accept losing in the past. “If the shape of the client had been cut too complex for hand, we refuse to work,” said Nathan Musgrove, an engineer applications for a manufacturer of foam Jefferson, Georgia and a regional design center test. “That has not happened since we installed the CNC machine. It can be cut with precision, even the most complex forms in 3D.”

Foam manufacturers, in Scottsdale, Arizona, with headquarters is a network of coast to coast from 14 institutions, the products formed foam form, packaging and components. Its products are used in foam packaging for products such as electronic equipment and appliances, but they can also be found in other applications such as bicycle helmets inside. The company has 250 employees, molds a full range of materials including expanded polystyrene (EPS), expanded polyethylene (EPE), expanded polypropylene (EPP) and copolymers that GECET, ARCEL and rm. These raw materials are like beads injected into molds, then the steam and swell solidify into the finished form. Foam Fabricators also produced heated flexible materials such as polyethylene, polyurethanes, polypropylenes, and the result of both molded and extruded.

The samples for testing

Each regional business design and installations, the test will come with packaging professionals and graduates equipped with the latest in manufacturing, drop tests, data acquisition computer equipped and CAD systems. When a client comes foam manufacturers with a new product to be packed, is the first step, to work with the company’s engineers to determine the appropriate hardware. As soon as he was selected, the engineer uses the customer’s specifications and CAD geometry to create a rough design of the foam insert. The engineer specifies equipment foam manufacturer, size and performance characteristics of the product and uses the SolidWorks CAD system to a 3D model of the original concept to create. At this stage, most customers will need 20 to 30 samples for drop tests. Some customers have conducted this examination by the foam manufacturers, while other samples to see and prefer conducting trials in-house. There was a further disadvantage in the production of samples by hand. Some of the forms, the customers need not be this way. asked, for example, a manufacturer of jet-ski manufacturer, has produced a froth flotation plant to make sheet, piece of foam, which is passed to the bow of a jet-ski four men to lift. “That part was very complex geometry and it was impossible to shape it by hand,” said Musgrove. “We were not able to make to the sample, we could not take on the labor market.” A third disadvantage is that the models are made by hand is not very accurate, since the cutting required interpolation between surfaces. That was acceptable, some customers, but others wanted more precision.

One of the largest foam manufacturer customers, which usually requires a large number of samples for its extensive test program was asked to examine the company, using a machine. CNC, the foam samples are cut as the company saw this, they found two options: machining centers, heavy and expensive, designed primarily for metal working and low-cost router could not require the precision manufacturer of foam. Then they found the Techno CNC router production Model 160 Techno Isel, New Hyde Park, New York, which offers a perfect compromise. The router is very accurate and robust, designed for production routing and drilling on a variety of materials such as wood, plastic, MDF, solid surfacing materials and nonferrous metals. The price and capacity of the system seemed perfect for Techno CNC Foam Fabricators has enabled the company has decided to buy it. The technical specifications of the Techno router they selected include a work area for the router 59 “x 50″ and the height of the Z-axis 12, a vacuum device table, 5 hp Columbo spindle and a gantry clearance height for the most part. The table contains a fast speed of 800 inches per minute, cut a force Z-axis 200 pounds maximum resolution of 0.0005 in. and repeatability and 0.003 inch / foot absolute accuracy.

automated sample preparation Production

Now, if a customer comes with a foam manufacturer request for a new product provides the technician the SolidWorks model, as in the past. But instead of creating a drawing, it exports the solid model directly in the CAM program Techno-router system. Originally designed for metallurgy, this CAM program for the foam because of its ability to complex contours generate suitable with little programming effort. The CAM program is the engineer command and the software creates the tool paths for cutting the sample. The only additional input necessary information such as feeds and speeds. Total programming time between the date of the SolidWorks model is imported into the CAM program as the system, ready to cut the foam varies between 30 minutes to two hours, depending on the complexity of the piece.

is determined after a piece of foam bearing on the Techno router meets the operator the “Start” and the sample is then carved automatically. The machine does not need supervision, removed except in the finished piece and a new block of foam, to repeat the process requires. With this machine, a typical order for 20 samples in two days. The orders no large sample of more support for production engineers . The machine is simply held on with stock delivered and lasts until the job completed.

is a manufacturer of foam was very pleased with the reliability of the Techno router. With only one regular lubrication, it works perfectly . Part of its reliability is based on materials used in their construction used. For example, the machine ball screw anti-backlash. have these screws provide excellent power transmission through the ball between the nut and bolt, and this type of contact for low friction, low wear and long life. The ball screws also make it possible to produce parts of the machine resolution of 0.0005 inches. In addition, the machine on steel bases relieved with hardened steel linear ways and ball screws with standard servos that the best performance of precision, the ability of the speed and durability built to offer the machine. This play system of a tree yielding produces very smooth movement and is an extremely rigid system that produces high quality cuts.

The customers appreciate the faster rotation of the samples . Those who require a high degree of accuracy in their samples to improve the Techno router noticed here. More importantly, customers who come foam packaging components manufacturer research are now confident that the company take on their work, regardless of the complexity of the shape of its parts. Because imports CNC CAD geometry and shape exactly replicated, regardless of the complexity, foam manufacturers not only to the simpler forms.

After Techno CNC router has fruit for Manufacturers of foam in a number of opportunities taken. faster turnaround time on test samples more accurately, satisfied customers, and the ability to have complex tasks, a CNC router allows the company to compete against other injection molders foam. “Making samples on a CNC machine is the norm in our industry, “said Musgrove.” techno with the machine, we find profitable this requirement. “