Tooling Foam (High-Density)
Generic / House Brand
Overview
High-density polyurethane tooling foam (30–50 PCF) used for CNC-routed patterns, mold plugs, and lost foam casting. Cuts cleanly with any router bit, no chip formation — only dust. Essential for composite layup molds and automotive clay model alternatives.
Properties
Difficulty
beginner
Flexibility
rigid
Layer Adhesion
poor
Enclosure
no
Heated Bed
no
Dry Storage
no
Pros
- No chip hazard — fine dust only
- Fast machining at high RPM and feed
- Excellent pattern accuracy
- Lightweight
- Can be painted and smoothed
- Cheap per block
Cons
- Fragile — can crack if clamped too tightly
- Dust is fine and floats — good dust collection essential
- Not structural
- Dissolves in many solvents (test before coating)
- Cannot hold tight tolerances on thin walls
Best For
- Composite mold patterns|Lost-foam casting|Prototype body panels|Architecture models|CNC training|Plug molds
Avoid For
- Structural parts|Precision machined parts|Exposure to solvents without testing
Storage
Store dry and protected from impact. Foam blocks can be glued together with urethane adhesive for large patterns. Seal machined surfaces with epoxy primer for smooth finish.
Brands
Freeman High-Density FoamLast-A-Foam FR-4515Precision Board HDU