Tool Foam was created in response to feedback from customers. I started designing the tool layout by taking photo of the tools in place along with a ruler for scale. That way I know I've put in the minimum amount of energy and thus minimized the chances of excessive "melt back" away from the centerline of the kerf. Test, test, test before committing your good material. Alternatively it may be treated with a filtration system first and then routed to an exterior environment. I couldn't find a source online for any grade of 1/2" Plastizote that was less than ~$7/sg. Railroad Rail Lantern / Sign Stand Split With Axe. :-). I hope readers won't find it too deep for a comment thread! Thanks! Pelican Foam Cut Outline. Beyond the general rules that slower speed or higher power takes more material and low frequencies are good for materials that char while high frequencies are good for things that melt, its largely a matter of trying some combinations to see what you get. The 1.06 micron wavelength is also the base choice for laser marking ceramic foams.Laser Power – Must be selected based on the processes that will be performed. They have 2 ft. x 2 ft. x 1/2 in. Our laser processing systems transform images or drawings from your computer screen into real items made out of an amazing variety of materials…wood, plastic, tile, fabric, paper, glass, leather, stone, ceramic, rubber and many more. The highest price per sheet is 19.99 for the 57mm, and starts at $9.99. The places I found it online have it for around $4/sq/ft. I agree that for particularly delicate instruments or those that are hard to clean, it's best to err on the side of caution and get pay up for foam that does not outgas. The carpet covered tile worked okay, but it's thin and more expensive than the other materials I tested. There are applications where the laser can provide an impressive alternative to conventional machining methods. The BobsCNC E4 Router Engraver Kit is … 6 years ago I swear I responded to your comment earlier but it's nowhere to be found. to start laying out the foam … was enough. The double thickness material cut well on the 60W Epilog laser at 20% speed, 60% power, and 1000Hz. It's way too much work to do this manually if you want to do a clean job of it. thick EVA foam is available at craft stores (locally here in the SF Bay Area at Michael's or JoAnn's). I wonder if it's possible or advisable to add to this Instructable or if I should just do a new one. (~610mm x ~1825 mm x ~8mm) roll is $8. I've found two tools that make it easier to trace. EVA foam covered with other materials is available at Daiso California, a Japanese dollar store (okay, truthfully it's a $1.50 store) . That said, it is a way to get some big pieces of foam to feed to the laser. The black foam you’re looking at is a material called EVA. The foam is tear resistant, does not absorb liquids and is resistant to most fuels and oils. The laser easily cuts through a variety of foam thicknesses allowing you to precisely cut inserts that fit your specific tools. I went on a hunt for other, less expensive sources for the same stuff. Thanks for the kind words and the comment. Didn't mean to take focus from your impressive work, just offer those inspired by it a possible option for materials. If you do this, it's best to convert the scan to a vector format (using LiveTrace in Adobe Illustrator or its equivalent) so you can tweak it if needed. I mostly use method 2 with the drafting lead. Today’s foam market consists of a multitude of different materials for a wide range of applications. EVA foam is available at Harbor Freight. So, I decided to make some. Turns out that the 2 ft. x 2 ft. (~610mm x 610mm) size includes the interlocking features! I've used all three options successfully. This is good information, not only for tools, but also for making custom inserts for painted miniatures used in table-top wargaming. PE should be fairly low outgassing, and in most applications for storing tools like these should not be an issue. Sheet size: 2' x 4' (+ or - 1"). It worked okay functionally. Historically, it's been the haze that ends up on your inner surface of your car windshield after it's cooked out of the PVC dashboard. The Fiber laser can cut through thin sheets of foam (up to 1/8” or 3 mm). This process is easily controlled digitally. Apologies for whatever I said in my earlier reply that made you think I was in any way unhappy with your feedback. It's not about getting the most tools in the box, but getting the most out of your tools. The laser easily cuts through a variety of foam thicknesses allowing you to precisely cut inserts that fit your specific tools. It takes a lot of time to measure and draw more complex outlines. Anybody have experience cutting foam with a lower power laser - say 20 watts? I have found a source of foam in a neighbor who operates a vehicle upholstery business. In order to get a thick enough insert to securely hold thicker tools, I laminated two layers of the foam together using 3M Super 77 spray adhesive. Laser Engraving of Foam The power of the laser beam can be limited so that it removes material (engraves) to a specified depth. Its not the same as Illustrator. Foams are usually made from polymers, but they can also be made from ceramics or metals. Most stuff sold as "tool box foam" is polyethylene (PE) or ethylene-vinyl acetate (EVA) and is way too expensive. A wide bottom-side kerf likely results from one or both of two causes: too much energy into the cut and/or the optics of the laser. You may already know what I'm about to describe about laser optics, so sorry if this is redundant. Whether your needs include having us create custom tool foam using a waterjet, having foam custom cut by us is no problem. BobsCNC E4 Router Engraver Kit with Router Included. I'm learning the GIMP to replace pshop but you need to follow some tutorials because you have to think about some aspects differently. Kaizen Foam separates between the layers creating a perfect fit for storing all your tools in drawers and on walls. We don't want PVC in the laser cutter due to the hydrochloric acid vapors produced during cutting. More about the craft foam in a later step.
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