Blocking Saw

The blocking saw is the first and most important step of the PU cutting process.

PU is supplied in very large buns. Many times a full bun is more material than a customer needs.The blocking saw allows us to cut smaller blocks that will give you a lower minimum quantity.

Sometimes PU is needed in a hard to yield size. By blocking the material into smaller sizes and then cutting the blocks in different directions will often allow us to utilize the material much more effeicently.

Remember! Better yield, better deal!

Slitter

A slitter cuts PU blocks into sheets. PU buns do not always run the same height and sometimes we can get more or less sheets out of blocks due to this irregularity. The quantity of your order may have to change to compensate for this variance. Our slitter can also cut a block into multiple thicknesses and quantities. This helps us utilize the full height of the block. It also allows you to mix your thicknesses to

match the blocks height. 

Flash Cutter

The flashcutter is another truly amazing machine. We simply draw a foam part, load its shape into the machine's computer, and the machine cuts everything from that point on. The machine can also determine the best layout to minimize scrap.You can even send us a DXF formatted file with your requested shape and our machine can cut it.This machine is used mostly for prototyping, low volume orders and shapes that require a straight cut edge.It can also cut very large shapes.This saw can cut up to four inches thick, 60" wide and 120" long. Most importantly the Flash cutter makes it simple and fun for us to explore mutiple design possibilities to solve the most challenging packaging problems. 

Die Cutter

When it comes to die-cutting, you will first need to purchase a steel rule die in order to operate the machine.

A die is nothing more than a special shaped blade like a cookie cutter at grandma's house.The press simply

pushes the blade through the foam to produce the shape just like pushing a cookie cutter through dough..

Die cutting is one of the most effecient ways to create a foam shape. Multiple shapes can be grouped together on a indivdual die. This way each hit creates a multiple piece set. Mutiple sets can be produced every minute which makes the die cutter the work horse of foam fabrication.

When foam is cut with a die cutter the machine compresses the foam which forces the cells in the center of the foam outward before the blades cut through the material. After the machine retracks, the foam returns to its original thickness and shape of the die. The foam edges will be concaved. The thicker the material the more concaved the edge will be. This is called CONCAVITY. When samples are produced there is no concavity because the samples are cut with a saw that does not compress the foam. Once the original saw-cut sample is approved the dies are ordered. Once we receive the dies, we create a machine cut sample for approval.Once we receive approval the full job can be run.. See CONCAVITY illustration

Profile Cutter

Our profile machine can cut specialty desiged contour shapes. A pattern is created and followed by a rotating textured wire blade that cuts the shape from the foam. If we made a simple 6" circle pattern and followed it's path, the machine blade would cut the circle shape creating a 6" cylinder that has the length of the block that was placed on the machine. The cylinders are then removed from the foam shaped scrap cocoon and they are moved to a smaller vertical saw where we cut the piece down to the desired thickness and/or length. The scrap is removed from the edges and the profiles are packaged for shipment.