General Information

Our custom built F.A.C.S. 4014

4-axis CNC Foam Cutter

Our process uses CNC motion control to precisely cut the airfoil shape. No templates are required or used. The leading edge of the core can be formed to the full airfoil shape as shown here, or it can be cut for a balsa or hardwood leading edge. This core is being cut from 3" thick 1# density white beaded styrofoam. Other types and densities of foam are available.

CNC or Computer Numerical Control has been used in aerospace and other industries since the development of Numerical Control technology in the late 1950's.

Our machines are controlled by MDSI OpenCNC© Software running on a standard office grade PC. The machine axes are driven by brushless DC servo motors which have an infinitly variable shaft speed from 0 to 5000 RPM. Our machines produces foam cores that have no wire marks or other surface imperfections that result with 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 52" x 18" x 96". It can produce cores of any size up to a 52" chord and a 96" length. Wing cores for giant scale racing and aerobatic model aircraft up to 55% scale are produced with accuracy and precision available only from FlyingFoam.com.

We now have 2 Custom Built CNC Foam Cutters.

The larger and newest addition is in the background.

Our CNC Cut cores are accurate and consistent in quality and size. Surface finish is greatly improved over conventional template cutting methods.

Wing tube hole are accurately cut and can be partial or full depth. We check each tube hole for proper size.

Our Custom built machines use industrial quality brushless DC servo motors and servo drives for superior speed and performance. Positioning velocity is in excess of 600 IPM and we routinely cut foam at 40 IPM.

Our custom built CNC foam cutting machines produce precision foam cores without the need for templates.