On Jan 20, 10:03*pm, "
wrote:
On Jan 20, 9:10*pm, "Tim Ward" wrote:

Perhaps I'm missing something, but why not just CNC machine an existing foam
block?

If you have ever tried to mill 2 pound foam you would understand :-)
It tends to tear and the "chips" cling to everything with static
electricity.

It looks like milling foam is not as much of a problem as I thought.
Just goes to show you that just because I/we haven't been able to do
something that it isn't possible :-)

http://www.theworkshop.ca/machining/...FoamMill16.htm

Using this guys existing setup and milling foam from something like
1/4" sheets and then stacking them all together just might work!

And the thought occurred to me that one could substitute a hot point,
like a soldering iron tip, to do the "milling"
===================
Leon McAtee