CNC stands for Computer Numerical Control. It is a manufacturing process in which pre-programmed software moves a router (or other tool) to cut or remove material in a controlled manner, creating a specific 3D shape or recess.

What materials are suitable for CNC routing?

CNC routing is suitable for shaping mid- to high-density closed-cell foams, including those manufactured from polyethylene, polyurethane, and EPS. Plastazote® in particular provides excellent results when routed, with clean, precise edges and shapes.

What is the process for creating foam products with CNC routing?

The CNC routing process follows a digital-to-physical workflow. First, a foam designer creates a 3D model using software such as Rhino, Fusion 360, or SolidWorks. Software then converts the 3D model into a set of specific coordinates and instructions that tell the machine exactly where to move, how fast to spin, and how deep to cut. Finally, the CNC router follows those coordinates, moving a high-speed spindle along three, four, or even five axes to carve the foam block into the final part.

What is the difference between CNC routing and machining?

The terms routing and machining foam are largely interchangeable when talking about foam conversion. The process may also be referred to as foam profiling, CNC cutting, or even milling.

Foam products

Foam Shapes

Foam products

Foam Shapes

If you need parts, components or material in specific sizes, shapes, or designs, custom-cut foam shapes are often a great option.

Foam shapes are typically soft, pre-cut foam pieces used for arts, crafts, and educational play. However, foam shapes are also suitable for parts and components, upholstery and furniture, promotional and retail items, film props or even applications such as soft play and gymnastics equipment. From simple geometric shapes to complex 3D parts, foam can be converted into almost any shape or size using a range of manufacturing techniques.

At Polyformes, we can supply foam sheets ready for you to process yourself, or manufacture finished foam shapes to your exact specifications. Whether you have a simple drawing, a prototype, or a complex design challenge, our team of experts will work with you to find the best material and production method for your application.

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Competitive pricing

Advantages

Benefits of foam shapes

The benefits of using custom foam shapes include:

Manufactured to your exact size, shape and specifications.

Available in a wide range of materials, densities and colours.

Suitable for simple or highly complex designs.

Lightweight and easy to handle.

Can provide excellent protection, insulation and flotation.

Cost-effective for both low and high-volume production.

Produced using a range of precision cutting and forming techniques.

A child playing with covered foam shapes at a soft-play

Foam shape experts

FAQs

Foam shapes can be as simple as a basic block, a disc, strips of material, or as complex as intricate 3D components for specialist applications. They are custom-cut or formed foam components produced in a specific size, shape, or design.

Foam shapes are popular across a variety of applications. Whilst this frequently includes arts, crafts and upholstery, other applications such as vinyl-covered foam shapes (ramps, wedges, and cylinders) used in soft play centres, insulation, sealing, flotation, sports equipment, or even industrial components are all commonplace.

Material converters can produce foam shapes using a variety of manufacturing methods. These typically include CNC routing, waterjet cutting, die cutting, moulding, thermoforming, splitting, and laminating. The most appropriate process depends on the design, material, volume, and finish required.

If you are a foam converter, product manufacturer or packaging supplier, and would prefer to process the material yourself, Polyformes can supply foam material in a range of different sizes, thicknesses, and densities. Alternatively, we can cut the material to your required dimensions before delivery. Either way, you can benefit from a confidential trade service.

A parent and their child using small foam shapes for an arts and craft project

Process

A partnership approach

We don’t just manufacture foam shapes and products – we gain a detailed understanding of our business and challenges before proposing a cost-effective solution that does exactly what you need.

Understanding

We discuss your requirements with you, gaining a full, detailed understanding of your project.

Develop

Using your products or CAD data, we develop a solution using appropriate materials.

Test

We provide pre-production samples for testing and assurance on fit and quality.

Manufacture

We manufacture your products in-house at our specialist foam conversion facility.

Support

We forge long term relationships, providing ongoing support and assistance.

UK foam converters

Why work with us?

At Polyformes, our experience, expertise, and in-house conversion equipment enable us to provide your business with a wide range of benefits.

UK manufacture

We manufacture your custom foam products ourselves, allowing us complete control over design, quality, and lead times.

Short lead times

Our process – from initial meeting through design concept, samples, testing and manufacture – is quick, easy and focused on your requirements.

Foam experts

You can rely on our team of knowledgeable, experienced foam experts to select the optimal foam material, design, and production method for your application.

Single source

As part of Macfarlane Packaging, you can source a huge range of additional packaging and products from a single, easy-to-manage source.

Vast experience

Our approach means we’ll always consider your budget and balance this against the required performance and technical considerations.

Sustainability

As well as using recycled material where possible, we also place a strong emphasis on removing unnecessary materials, weight and volume from your products.

Wide range of options

Similar foam products

Disclaimer: Generative Ai may be used on this site when specifically creating content and information relating to the products, processes and materials we use at Polyformes. Any Ai content undergoes stringent reviews and editing by humans to check accuracy. Please view this content policy for further details.

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If you need high-performance foam inserts, packaging, products or materials, we can help. Please contact a member of our team for a free consultation and quote.

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Our experts

The information on this page was written and checked by our team of experts. You can contact them to discuss your requirements, or for any questions you may have, using the details here.