Our custom built CNC foam cutting machine produces high quality, precision foam cores without the need for templates.
CNC or Computer Numerical Control technology has been used in aerospace and other industries since the development of Numerical Control technology in the late 1950s.
Only recently has the cost of CNC come down to a level where it is possible to apply this technology to foam core production. Our machine uses MDSI's OpenCNC Software running on a standard office grade PC and Windows-NT to control the cutting process. The machine axes are controlled by brushless DC servo motors which have an infinitly variable shaft speed from 0 to 5000 RPM. This machine produces foam cores that have no wire marks or other surface imperfections that result from typical template cutting methods.
Our machine uses a software programming system that was custom written specifically for this process by flyingfoam.com.
The machine envelope size is 30" x 8" x 63". It can produce cores of any size up to a 30" chord and a 63" length. Wing cores for giant scale racing and aerobatic model aircraft up to 45% scale can be produced with accuracy and precision that has not been available until now.
FREQUENTLY ASKED QUESTIONS:
OK, this sounds great, but isn't it expensive?
Answer: Because our CNC foam cutter does not require templates, there is no setup charge, even for a single set of cores. We simply enter your specifications into our programming system and the machine is ready to cut. You pay only for the cost of the foam material, machine time and shipping. As an example, a pair of wing cores with a 12" root chord, 9"tip chord and a 30" span, cut in 1# density styrofoam will cost $31.13 + shipping and tax. This is little more than the cost of two blocks of foam purchased at your local plastics store or hobby shop.
What types of foam are available?
Answer: We have EPS (Expanded PolyStyrene or Styrofoam) in 1#, 1.5# and 2# density, and Blue Dow Styrofoam in 2# density. We also have EPP (Expanded PolyPropolene) in 1.3# and 1.9# density.
How quickly can I get my cores?
Answer: Most orders are processed in 1 to 2 weeks. We typically ship cores up to 24" in length via U.S.P.S Priority mail, which has the same delivery time as a 1st class letter for usually less than $6. We ship via U.P.S. and can ship overnight for next day delivery, however these shipping charges will be higher.
How many different airfoils can you cut?
Answer: We have several hundred airfoil profiles to choose from. We also can generate NACA 4, 5, and 6 digit airfoils. We can also cut any airfoil that has been designed or modified in Compufoil, or stored in Compufoil (.cor) file format.
Can you cut spar slots and/or wing tube holes?
Answer: Yes, for a small extra charge.
Do you offer discounts?
Answer: We encourage volume orders from kit manufacturers, or for club projects by offering discounts that increase with size of the order. We also will discount repeat orders for cores that are identical to a previous order and shipped to the same address.
I can't wait! How do I order custom cores?
We need a number of pieces of information to create your cores. For wing cores, the following information is required:
1. Root airfoil and chord length
2. Tip airfoil and chord length
3. Length of wing panel (per side)
4. Setback of tip airfoil (amount of sweep back at leading edge)
5. Washin or washout (both root and tip if applicable)
6. Dihedral specification
7. Sheeting allowance
8. Leading edge length
9. Trailing edge length or thickness
10. Additional cuts for wing spars, wing tubes, etc.
11. Type of foam
(1# white, 1.5# white, 2# white, 2# blue, 1.3# EPP, or 1.9# EPP)
12. Quantity (1 set is just fine!)
Since you may not know all of this information, here are some ways you can supply this data to us:
1. Provide plans, drawings, or sketches
2. Use Compufoil to design your wing, and provide us with the template plots, or the Compufoil files.
FlyingFoam.com will quote your job by fax, or email.
or
fax your sketches to 909-324-8206,
or
mail your plans or drawings to:
FlyingFoam.com
Attn: Custom Core Service
9990 Indiana Ave. #7
Riverside, CA 92503
