Prototype Foam Milling

Our seven axis Kuka CNC robotic milling cell allows for accurate and rapid milling of soft and rigid foams, expanded polypropylene (EPP), tooling boards, resins and polystyrene.

Having the in-house ability to mould bespoke foam blocks to given hardness, density and flame retardancy allows for a flexible solution to milled foam parts.

Milled foams can include High Resilience Flexible Foams to FMVSS302, CMHR flame retardant to Crib 5 – BS 5852 and Graphite Foams flame retardant to CRIB 7.

Our huge Robot milling cell with rotary table plus Autodesk® PowerMill Robot software brings a high level of flexibility for fast accurate robot milling of foam seating and interior trim, sculptures, statues, exhibition, point of sale models and large-scale artwork, scaled up models and patterns for advertising projects, film and television production and commercial events.

Our Robot is capable of producing the highest quality complex and unusual geometries including complex undercuts and 3D objects with a massive reach and 3D workspace that includes a 10-station tool changer giving automatic flexible tooling selection for specific material removal.


Milled seat foams

Robotic CNC milled prototype seat foams, headrests, armrests and soft trim, ideal for early prototypes, concept and show cars, milled seating and soft trim manufactured from CAD.

Milled seat foams are CNC machined from in-house pre-moulded blocks allowing us to match the production PU foam system plus hardness and density.

CNC machined foam seats can include dual hardness and inserts eg.. clips, trim wires, velcro and wire frames to represent production moulded seat foams.

Milled into pre-moulded foam blocks to the correct hardness and density with a hardness range typically from 4 – 25 kPa and a density range 50 – 125 KgM3.

CNC milled foams are an ideal solution allowing for quick manufacture of foam seating for comfort and design evaluation prior to progressing to rapid prototype foam moulding.

  • Seat foams milled from CAD to part in days
  • Milled from pre-moulded foam blocks to match production PU system
  • Hardness and density controlled
  • Dual hardness seat foams
  • Includes all inserts
  • Rapid quote, rapid parts
  • Ideal for early prototype, show car and concept cars
  • No tooling investment required

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