CNC Machining Foam

What is Electrolysis and galvanic corrosion?

Galvanic Corrosion is the corrosion that occurs when two dissimilar metals are used together in a structure and exposed to an electrolyte (salt water, chemical, petrol) and the less noble of the 2 metals will corrode. For example; aluminum sheet with steel fasteners on a boat. Some pairings of metals are more at risk of . Check a galvanic series or chart.

Electrolysis is the acceleration of the galvanic corrosion when electricity is introduced to the metals in question. Connected by an , the less metal experiences accelerated galvanic corrosion.

while both processes involve metals and electrolytes, their dependence on an external voltage source distinguishes them.

If you’re evaluating a cnc machine for foam parts, start with process fit. PJ Bowers combines CAD, rapid prototyping, and multiple CNC methods—routing, knife cutting, waterjet, and wire profiling—so you move from concept to clean, repeatable components efficiently.

Many custom foam case inserts that would have required professional manufacturing

Why CNC for Foam?

Foam behaves differently from metals or timber; consequently, you choose the process to match geometry, tolerance, finish, and volume. With the right setup, you improve yield, reduce rework, and keep edges crisp—especially on multi-depth pockets, radii, and long profiles. Capability overview: https://www.pjbowers.com.au/services/our-services

CNC Methods we Run in House

CNC Routing - Removes material precisely for trays, pockets, chamfers, and bevels. Ideal for case inserts and multi-layer assemblies where accurate depths matter. More: https://www.pjbowers.com.au/services/our-services

CNC Knife Cutting - High-speed knife cutting delivers fast, accurate 2D profiles with minimal kerf—perfect for silhouettes that don’t require pocketing. More: https://www.pjbowers.com.au/services/our-services

CNC Wire Profile Cutting - Cuts complex 2D shapes without heat-affected edges. Excellent for intricate gaskets, logos, and detailed panels. More: https://www.pjbowers.com.au/services/our-services

Splitting and Skiving - CNC-controlled splitting to tight thickness tolerances. You can dial in weight, buoyancy, and stackups without over-machining.

Laser Cutting and Etching - Add part IDs, logos, and shadow labels—handy for visual tool control and kitting. More: https://www.pjbowers.com.au/tool-control

Design to Delivery Workflow

First, our engineers create CAD and toolpaths. Next, we prototype so you can test fit, handling, and protection. Then we scale to short- or long-run manufacturing with ERP-tracked quality, kitting, and distribution as required. Full services: https://www.pjbowers.com.au/services/our-services

Foam materials we machine

• Neolon® XPE: buoyancy, insulation, durable protection.https://www.pjbowers.com.au/products/neolon-foam
‍• Neofoam® PE: structural packaging, firm pocket walls.https://www.pjbowers.com.au/products/polyethylene-pe-foam
‍• Neofoam® EVA: elasticity and rebound for impact-friendly inserts.https://www.pjbowers.com.au/products/eva-foam
‍• Ethafoam®: inert, non-abrasive supports for conservation and handling.https://www.pjbowers.com.au/products/ethafoam
‍• Zotefoams Plastazote® / Evazote®: consistent, technical performance.https://www.pjbowers.com.au/products/plastazote-evazote-foams

Applications we deliver

• Tool control: custom shadow-board inserts with laser-etched IDs and variable pockets.
https://www.pjbowers.com.au/tool-control
• Protective packaging: engineered case inserts for instruments and electronics.
https://www.pjbowers.com.au/custom-foam-inserts
• Marine & transport: shaped buoyancy, fenders, and profiles for harsh environments.
https://www.pjbowers.com.au/industries/marine
• Construction: precision strips, joint fillers, and seals that install cleanly.
Stiff joint filler (PE120): https://www.pjbowers.com.au/products/stiff-expansion-joint-filler
Bridgefoam® expansion joint: https://www.pjbowers.com.au/products/bridgefoam-neolon-expansion-joint
• Medical & archival: cut supports and mounts where purity and surface finish matter.

Bridgefoam items stacked on top of one another

How to spec your CNC foam job

1. Share the CAD: STEP/IGES/DXF plus a simple drawing with depths and radii.
2. Pick the material: match foam type and density to environment and load.
3. Call tolerances early: specify thickness, pocket depth, kerf, and edge quality.
4. Plan finishing: add laser marks, hard tops/backs, or lamination as needed.
5. Decide volumes: we prototype rapidly, then scale to production.

Ready to Cut

Talk with our engineers about the right cnc machine process for your foam part.
• Custom Foam Inserts: https://www.pjbowers.com.au/custom-foam-inserts
‍• Our Services: https://www.pjbowers.com.au/services/our-services
‍• Request a quote: https://www.pjbowers.com.au/contact-us
‍Prefer to buy sheets online? FoamProducts.com.au: https://foamproducts.com.au/

FAQs

Which cnc machine should I use for foam pockets?
A: Use CNC routing for variable-depth pockets and bevels. Choose CNC knife or waterjet for fast 2D profiles. More: https://www.pjbowers.com.au/services/our-services

‍Can you handle short runs and scale later?
A: Yes. We prototype quickly and then scale to short- or long-run manufacturing with ERP-tracked quality and logistics.

Do you laser-mark tool silhouettes?
A: Absolutely. We can laser etch part numbers, artwork, and pocket labels for visual tool control: https://www.pjbowers.com.au/tool-control