Do You Offer Rapid Prototyping PU Foam Parts?

Rojac offer a number of solutions for rapid prototyping and development of foam parts.

CNC Machined foams

For rapid development of foam parts Rojac utilise a 7 axis Robotic milling cell to CNC machine foam straight from the CAD utilising Autodesk PowerMill and PowerShape.

Complex 3D parts can be milled directly from soft to rigid foam materials including flexible and rigid foams, EPP, tooling boards and polystyrene, we also have the in-house ability to mould PU foam blocks to your required density and hardness to match production PU systems and mill these for your 3D parts.

This method is widely used for seat foam development where seat foam parts can be machined from soft flexible foams for concept cars, early vehicle development and prototypes.

We have the ability to add a synthetic skin to milled foam parts replicating prototype or production moulded foams.

No tooling investment is required for milled foams as we go straight from CAD to machined parts, full seat foam sets can be milled in days.

If you don’t have CAD data we can scan sample parts and reverse engineer back to CAD data

  • From CAD to Milled PU foams in day not weeks.
  • CNC foam cutting 7 axis robotic milling of soft and rigid foams, EPP, tooling boards and polystyrene.
  • Parts milled to required hardness/density from pre-moulded blocks.
  • Dual hardness parts if required.
  • Prototype machined foams.
  • Inserts, wires, clips, velcro included in milled foams.
  • Synthetic skin can be added to machined PU foams
  • No tooling investment
  • Complex 3D parts.
  • Complete car sets machined, including front seat cushion, squab, headrest, rear seat 40% and 60% squabs, full rear seat cushion, armrests, bolsters and inserts.

Rapid Prototype foam moulding

The ideal solution for prototype and development of polyurethane foam mouldings.

This process is often used to follow milled foam parts for development and prototypes where a number of prototype parts are required.

This process has been successfully utilised for many automotive vehicle seating projects allowing our customers to rapidly develop seat designs, foam hardness and comfort trials in a fraction of the time traditionally taken to develop seating for new vehicles.

  • From CAD to moulded PU foam mouldings in 7-10 day.
  • Mould multiple foams from the same tool
  • Parts moulded to required hardness/density
  • Dual hardness parts if required
  • Production intent moulded foams
  • Inserts, wires, clips, velcro moulded into foam
  • Tools can be easily modified (material on or off tool)
  • Production intent parts early in development stages of the project
  • Complete car sets moulded, including front seat cushion, squab, headrest, rear seat 40% and 60% squabs, full rear seat cushion, headrests, bolsters and inserts

Rojac Urethane Limted offer a number of solutions for rapid prototyping and development of foam parts including CNC Machined foams and Rapid Prototype foam moulding. Contact us for further information

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