CNC (Computer Numerical Control) Routing is a highly advanced method of routing plastazote and other expanded polyethylene packaging foams using CAD (Computer Aided Design). In simple terms, it’s a powerful piece of equipment that cuts through materials with ease, speed and accuracy with consistent repeatability.
This technique of foam cutting has numerous benefits, as it’s computerised programme allows for precise and complex shapes to be precision cut at speed and provide a consistent, high-quality finish and exact fit for products within our custom foam inserts ebery time whether they are to be used as protective packaging foam or presentation foam inserts.
Keep reading to discover how and why CNC foam cutting is so effective and efficient at reducing the costs of your industrial solutions.
Why We Choose CNC Foam Cutting?
CNC foam cutting is a highly popular and effective solution used for padding the interiors of custom cases and bags for various commercial products, equipment and samples. Due to the high quality precise finish this cutting solution offers, it carries a reputation for versatility and is commonly used to create a wide array of packaging and presentation solutions, including:
- Promotional sales & marketing sales demo kit cases
- Reps sample presentation cases
- Protective product transit packaging
- Maintenance, service and repair equipment (e.g. tool control dual colour foam inserts and boards
- Medical, healthcare, research and pharma
- Critical safety or security equipment
- Instrumentation, test & measurement equipment
What Makes A CNC Router So Effective?
Instead of routing by hand, CNC Routers are controlled via a computer. A CAD (Computer Aided Design) System allows a path to be created that produces the products. Unmatchable precision and automation are the two main benefits of this tool, setting it apart from the competition.
The CNC router is one of many tools that have CNC variants, however this particular device is a computer-controlled cutting machine which can be used for a wide variety of materials – e.g. wood, aluminium, steels, plastics, foam, glass and materials.
How Is CNC Foam Cutting Cost Effective?
Perhaps the most pertinent benefit of CNC foam cutting and what makes it such a popular solution is its efficiency by producing high quality, reliable products every time. There are various other benefits that feed into this use of CNC routing solutions, including:
Producing precise and accurate results every time through being able to rely on the precise scale measurements of the technology. In the past, hand-held cutting solutions would have left the finished article far more susceptible to human error.
Lower labour costs are ultimately achieved through the reduction of manpower or workers required for the cutting process – allowing the machinery to get the job done for far less cost. Usually, the minimum that is required is a small team to initially programme the device to suit your needs and initiate your projects and then to monitor the equipment in the (unlikely) case that any errors should occur.
A quick turn around of producing new products is achieved through this highly efficient technology minimising the time which it takes to produce the product and get it onto the market.
CNC router hugely reduces the frequency of human error – ensuring the highest standard of finish on every item and also reducing waste. Thanks to the safety features installed in all CNC routing there less chance of both accidents or human mistakes occurring.
Digital, convenient training is another major benefit. The human element of this process being removed through the use of technology. Therefore, hands-on training is not a necessary part of using CNC foam cutting as the programming and control is taught online or by computers. This improves efficiency by minimising human resource and labour costs further.
How Does Computer Aided Design Help?
One of the reasons CAD is such a popular industry solution for designing and cutting foam inserts is that it has the ability to automate 3D imagery and integrate different components of the same product in tandem with each other.
At Potterton Pacs we use Computer Aided Design across many of our product ranges and bespoke creations. For example, we cut a high proportion of our presentation foam inserts with the use of CNC cutting. Plastic carry cases with custom foam inserts are cut with precision, using the exact dimensions of the products or equipment that need protecting.
Our vertical bandknife and bandsaw enable us to convert large polyurethane foam blocks 2.4m x 2m x 1.15m block into sheets and also allows us to create custom sized square or rectangular foam insert pads to be used as protective packaging inserts to protect items in transit.
The more technical foam materials we convert are usually but not exclusively:
Polyurethane foam, also known as PU foam: Polyurathane/PU foam is usually medium density open cells foams. This kind of foam is ideal for custom foam for use as protective packaging foams inserts to go into cases or the clients packaging boxes with custom cut outs to provide organisation of products. This foam is well suited to items which are not too heavy or do not require the highest level of protection.
Polyethylene foam, also known as PE foam: Polethylene/PE foam is a closed-cell foam which is very firm (high density). It is also a very resilient foam which provides chemical and water-resistant properties, whilst also offering the highest protection against damage, vibration dampening and insulation. It is commonly used for heavier bulkier items that need protective packaging solutions such as tool kits and industrial or commercial items.
All of the foams detailed above can be converted or custom cut by utilising one of our custom cutting pieces of machinery which include a CNC Router, waterjet cutter, profiler and die cutting press. This specialist cutting machinery enables us to produce the more intricate shapes required for some custom foam insert projects and allows the foam to protect or present the items within precisely.
What Type Of Foam Is Used?
Polyethylene foam (of which Plastazote is one widely recognised brand name that we offer) is highly versatile – produced as a by product of oil – and is one of the most commonly used selected for CNC foam insert cutting.
What Is The Result?
This technology is used to produce bespoke custom cut foam inserts with cut outs to create recesses for products to be used within protective or presentation cases or padded equipment bags. The highly versatile nature of CNC routing means that bespoke interior designs can be customised to suit the specific needs of your business’s products or equipment.
Feeling convinced about the wide reaching benefits of CNC foam cutting for your industrial needs?
At PottertonPacs we use the latest technology to provide an unparalleled design and production service for all your custom foam insert, presentation and transportation requirements. Curious to see our products for yourself? Make sure you pay a visit to our showroom to discover our various packaging, display and transit products including our custom flight cases, plastic carry cases, padded equipment bags and the numerous types presentation and packaging foam inserts available.
