I have been trying to cut Foam Board I purchased at Dollar Tree for a foam airplane. I was surprised that my Atomstack A20 (supposed to have the 4 diode power rating equivalent to cut through 15mm of wood) doesn’t make a scratch on the foam even at 100% power. It will do a number on the paper and so I know it is working, but the white foam underneath the black paper is virtully untouched. I peeled the paper off some and tried and it doesn’t do much. 100mm speed and full power seems to make some cutss, but not all the way through.
So I assume foam is not able to be cut with laser power unless a CO2 laser with more power? Or, does foam just melt. I did see bubbling on the bottom of the parts when I tried to cut with the 100% power and slow speed.
From my experience trying to do this with a lower power diode laser it was basically impossible as you found. As far as I’m aware all dollar tree foam board has white foam. I suspect between the color and structure of the foam basically all light is either reflected or otherwise dissipated.
Even if you could work your way slowly through it I suspect it would leave an ugly mess.
Thanks for that confirmation. I suspected as much but wasn’t sure. I’ve used a CO2 laser before and thought this might do the trick as well. Looks like I’ll have to go to my CNC router with a small bit.
Well, now! I’m already looking and I think you may be on to somthin’! Thanks for the tip. Part of my problem is I will think about making a model plane, then wish I had a better tool to cut the parts, then find a new flashy thing to build that will help me build the planes… well, you see where this is going… just finished my medium format CNC machine I scratch-built, then needed the laser to etch the projects and cut balsa/foam… and now a needle cutter which looks like a nice addition.
SInce you already have a CNC and are familiar with RC components, you can be up and running in pretty short order. All you need is a suitable 1000-1200kv brushless motor, working ESC, a servo tester (used as the motor speed controller), and a Lipo battery or 12V power supply… most/all of which you probably have in your stash/junkbox already. Hopefully you (or someone you know) can 3d-print a cutter body and find suitable hardware to complete the assembly. Since you scratch-built your CNC you can probably do it for less than $20 or so…
Here’s a pretty good video, using a similar cutter design, and adapted to an OX CNC machine… and he does a pretty good job of showing what all’s involved. There are numerous workable flows for getting your design(s) ready for cutting and once you’ve done it a few times it becomes quite painless; i.e. quick and easy. Jump to the 19 minute mark to see it in action…
Many thanks for the suggestion. I have spent the last day/evening looking at this project and thanks to you will be building something to attach to my existing CNC.
I have access to several 3D printers at the university library and plan to make something soon. My summer break starts tomorrow so I hope to dive in soon.
