FOAM CARVING

A trade fair character or a fascinating lobby exhibit may have intrigued you. Yes, but not the sort your pillow is made of. For these unique and bespoke sculptures, foam cutting and carving is required in addition to the foam. They may be used to carve shapes, letters, props, and figures out of foam (from little to huge). Imagine foam cutting an 8′ high white foam block into a colourful and intricate work of art. We create decorative sculptures with foam by hand. To automate 3D foam carving, we may utilise foam cutters and CNC equipment.

As a result, foam is one of the most often used foam carving and sculpting materials. Whether for trade exhibitions, museums, theme parks and attractions, retail shops, office complexes, lobby displays, artificial landscapes, or special events, carved foam sculptures may create a realistic and inspiring finish. These can be done exclusively by foam artists.

Preparation/Setup of Carving Foam

It all starts with a 3D model. Our in-house designers and statue makers construct a 3D model utilising a modelling tool. They are used to confirm that what we produce meets consumer expectations. Then the sculpture is planned and mapped out using this file. The file gets increasingly important as the sculpture grows. It is common to glue huge portions of foam together before carving to create a beautiful foam art.

Before carving, most carvers create a grid on the foam. In addition to free-hand sketching, this grid system may be achieved by printing scaled-up gridlines from a 3D design and putting them to the foam, or by projecting an illuminated picture from the 3D design on the foam and tracing it. Structures within the completed piece may need a steel or aluminium structure to offer strength and mobility for bigger farm carvings or decorative sculptures that require movement or several installations. 3D models have stiff frames. The strength and weight requirements generally govern the use of steel or aluminium and the size of these structures. They may be permanently welded or placed with detachable components, like kitchen sink plumbing. A sculpture may be suspended from a ceiling using the frameworks. Using foam glues, these robust constructions may be simply bonded to using foam.

Material and Technology

Technology allows for more spectacular next-generation foam art. A model or statue maker may create amazing models by combining traditional methods of foam carving, sculpting and cutting with 3D printing.

Different Foams

In general, we employ two kinds of foam: HD and EPS (EPS). These include architectural and landscape models, as well as several props. But it’s harder to hand-carve. CNC machines usually automate the cutting of high-density foam and create decorative structures and statues.

This is normally the white foam that is utilised for most of our hand-carving. Extruded polystyrene (XPS) foam is sometimes carved. “Blue foam,” “pink foam,” styrofoam and are the most common brand names these foam artists create things on variations on this theme. XPS is commonly available in local hardware stores. Easy to use EPS Adding dowels, PVC, or metal rods to the carved sculpture adds structure and stability and is simple to achieve with EPS foam materials.

EPS foam comes in 1lb, 2lb, and 3lb densities. These weights specify the final foam’s weight per cube. Other densities, from.5 lb to 6 lb, may be carved. EPS foam is available in huge white chunks weighing 300-900 pounds. To carve delicate features, 2lb density EPS foam works well.

Carving Foam Tools

Starting to foam carve for the statue makers might be simple or challenging depending on the equipment used. Choose well to carve foam, you may use heated wires or a band saw or use a CNC cutter. Use tiny hand tools to conduct finer carving and sanding. Like a hot knife into butter, the hand carving tools feature tiny wires with electricity running through them to melt the foam. Custom carving is made simpler using instruments that include hot wires. Cutting foam is considerably simpler with the correct tools and creating foam art. Making foam carving simpler requires the correct skills. Drawing and model-making abilities are also highly beneficial. The act of cutting foam may rapidly get messy and can only be done by experienced foam artists.

Finishes

When sculpting foam sculptures, there is always a dispute. What’s harder? Making the sculpture beautiful by carving it or finishing it. The most challenging component of a carving is making raw foam appear like it isn’t made of foam. Some points to ponder include:

Foam is weak and fragile. The sort of strength coating to be applied requires a lot of thinking. Varying degrees of durability may be achieved using soft- and hard-shell coatings, and sealants like urethane. If the completed foam carved sculpture will be outside, fibreglass coatings may be added. Coatings like Habitat may be used if strength and submersion are required.

Foam Use

Themed models, statues, animals, monsters, murals, props, architecture, dioramas, letters/numbers, distinctive foam forms, or unique displays are all possible. For example, they may bring an animal or setting to life, recreate a movie scenario, draw tradeshow attendees, or create a mystical atmosphere. Only your imagination limits you.

Characters in 3D

No one wants to miss out on a chance to take their own photo with their Incorporating realistic accessories and surroundings into 3D figures is easy with carved foam. Carved foam is fantastic for making fast and affordable props, armour, weapons, and animals. To mention a few uses for carved foam: movie sets, theatre sets, haunted exhibits, amusement park backdrops and constructions, churches. Fabrication of realistic sceneries or buildings with rich backgrounds is possible with foam. Foam is lightweight, inexpensive, and fast to fabricate. You may design your own forms to suit your ideas and