Foam Construction Methods

Die Cutting

Ideal for high volume repeating applications we offer a full range of die cutting capabilities to include the precision kiss cutting of parts with pressure sensitive adhesive.

Die cutters operate similar to a large-scale cookie cutter. They are capable of cutting exact shapes out of foam. Dies, also known as plates, are made by insetting thin, finely serrated blades into wood to create a cutting pattern. Sheets of foam are placed over the plates and compressed by up to 80 tons of pressure. The foam is forced down over the plates, cut to shape and released, creating a form matching the plate’s exact design



CNC Routing

CNC systems route all polyethylene and closed cell foams including E.P.S. This process uses a high speed router that follows AutoCAD drawings to produce complex foam cavities.



Waterjet Cutting

Waterjet cutters use the power of highly pressurized, abrasive–free water and the precision of computer programming to create products that require a high degree of detail. With a jet of water pressurized typically to  60,000 psi, traveling at three times the speed of sound, they are able to cut through foam products up to 4 inches thick. For perspective, a die cutter is able to slice through a 1/2 inch piece of plywood on standard foam-cutting settings with a jet only .005 inches in diameter. After a pattern is programmed, the foam sheet to be cut is placed on a bed of 7 inch corrugated plastic that diffuses the jet’s stream. The nozzle hovers over the sheet, tracing the form’s outline with the jet, cutting through the foam cleanly. While they both provide the same level of precision, the waterjet cutter is for lower volume products than the die cutter. This is because the time it takes to trace every cut takes minutes, while a single pressing on the die cutter takes seconds. However, because the waterjet cutter requires only computer programming, it carries a shorter lead-time than the die cutter, and is costs less than creating press plates. Waterjet projects are typically limited volume products like prototypes, specialized packaging forms, gaskets and toys.



Fast Wire Cutting

Fast wire cutters provide the ability to cut complex profiles in a wide variety of materials up to 60” long. Common applications are rack cladding or pipe insulation.




Skivers cut foam into sheets as thin as 1/16 of an inch and as thick as 5 inches as they shave foam into layers or slices. Because of the density of the materials cut with the skiver, the blades used are substantial, typically at 3.3 inches wide, .04 inches thick and constantly self-sharpening. Considering the materials it must cut, skivers are incredibly powerful machines. These manually fed and can handle large widths, with no limit to the length of the sheet. For especially long sheets, skivers can be fed from rollers. Skivers needs to be programmed to cut to a certain thickness, but not to the degree of a CNC machine or the water jet cutter, as the saw blade remains stationary once programmed to its desired setting. Since skivers can only cut horizontally, products may be cut to size on vertical saws, water jet cutters or die cutters. Products produced from skivers include high-density packaging, flotation devices like life jackets and sports matting and padding.



Additional Services

Assembly and Fulfillment
Bald Eagle provides turnkey solutions to your case and foam requirements.

PSA Application
We can provide the most cost effective methods to bond your parts.

Post Processing
This term captures an infinite array of activities once the basic shape of the part is cut. This includes, T-slotting, shaping, taping, as well as drilling and countersinking holes amongst others.

Call Bald Eagle today for all your Packaging & Shipping Service needs.

Leave a Reply

Your email address will not be published. Required fields are marked *