How to Prototype Molded EPP Foam Parts?

[goldenfab]

I have an engineer contact that reached out to me regarding getting some prototype parts cut from EPP foam. I thought about mounting a wood router to my mill but I'm not sure it's worth the trouble and refered him out to a local shop that has a 5 axis router.

Is there a way to mold prototype EPP foam parts without specialized equipment? I've seen 3d printed mold inserts can be used for prototyping injection molding hard plastics and I've seen the really basic small low pressure injection molding machines for hard plastics and they have decent results when they are used within their constraints. Is there a way to accomplish the same with EPP foam?

 

[technocrat]

EPP foam beads are heat processed with steam or RF in your 3d print or other mould. Otherwise for lesser results it can be machined.

 

[LOTT]

Can you use a urethane? There's a huge variety of types and properties out there, and for a prototype there's a lot of methods you could use to make molds.

 

[EmGo]

Is there a way to mold prototype EPP foam parts without specialized equipment?

Design Octaves, Santa Cruz, CA. It's urethane but this is what they do, they have a list of happy big name customers as long as your arm and they are good at it.

 

[Comatose]

RYOBI USB Lithium Hot Wire Foam Cutter Kit with 2.0 Ah Lithium-ion Rechargeable Battery FVH64K - The Home Depot

RYOBI introduces the USB Lithium Foam Cutter Kit. This tool cuts, shapes and shaves a variety of foam. Rapidly heating up in under 2 minutes, this tool is ready when you are. The dual heat settings give

www.homedepot.com

Hundred bucks. Go nuts.

Or a power supply, a piece of stainless steel wire, a stick and two eye bolts.

 

[Houdini]

EPP Molding