FROGBlog - 3D Foam Carving Central

We've highlighted our client DragonXtreme's (www.dragonxtreme.com) fantastic work before, but the range and quality of 3D carving projects that owner Joe McPeek continues to pump out is nothing short of amazing. It's also a testament to the wide range of projects that automated foam carving can handle.  Some of DragonXtreme's recent work includes custom made mannequins and molds for Lamborghini wings. Nice work Joe!
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So, after posting a foam carved replica of Yoda, we wanted to come back with a client project that has a bit of scale to really show the enlargement capabilities of automated 3D foam carving. But what could we show that illustrates that the system is capable of creating something as big as a whale? After racking our brains, we figured that this would be best illustrated with a big whale.
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When fans of 3D foam carving get excited, they're usually talking about their end products or the technologies they're using to get to the end product.  But where's the love for the actual raw material that forms the basis of any foam carving project? In the spirit of bringing recognition to this oft forgotten material, we're always on the lookout for new and improved foam products. To that end, we've been experimenting with vegetables - seriously. We got our hands on a soy-based foam product that's not only environmentally friendly, but that does a pretty good job when it comes to 3D milling. We took a relief file and tried out this new foam with some pretty good results (see below).  What's more, the product is edible. One of our techs took one for the team and tried it out. The result? Uhhhh, not so good.
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Advances in 3D design software are making it easier to bring dimension to flat images and photographs. From a 3D foam carving perspective, this is opening the door to a range of new applications and possibilities. We recently completed a sample relief project that gives a sense of what's possible. The original picture used for this project sits in the top right of the photos.
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The world of automated foam carving revolves around some pretty advanced equipment. It's no secret that many folks hesitate to invest in this kind of equipment (or any kind of machinery for that matter) when the economy is struggling. More often than not, it's the businesses that invest in their companies during economic downswings that come out of the downturns the most prepared to dominate (here's a perfect example).

Seems that more businesses are sensing an economic recovery and are more willing to invest in equipment and machinery. According to a story from one of our local papers in Calgary, businesses (at least those in Canada) are sensing an economic recovery and getting a jump on investing in their businesses. A sign of good things to come?

Read the Calgary Herald article here.

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The coating stage of the foam carving production process is a critical one. Proper preparation and procedures (where's Porky Pig when you need him?) can mean the difference between a project that can withstand its environment and one that falls prey to the elements. Coating is also critical for giving your project the look it needs. Our most recent article offers up some things to consider when applying protective coatings to ensure your project has both staying power and good looks. 

APPLYING PROTECTIVE COATINGS TO FOAM CARVING AND CUTTING PROJECTS – 5 THINGS TO CONSIDER

If you’re in the foam cutting or carving business, you know the importance of the protective hard coating process (and if you don’t, you should). For those just getting started in the industry, be aware that it’s often an overlooked step that doesn’t get the attention it needs. To avoid costly product failures and rework, proper preparation is absolutely critical. Let’s assume that your foam piece is cut and you’ve selected the most appropriate coating for your project. Before you start spraying, there are a few things to consider that will help you avoid some of the most common application problems.

1. Thickness
Don’t press that trigger until you know how thick you’ll be applying your selected coating. The thickness of the coating will not only determine the durability of the final product, but it’s also going to have an impact on the final weight of the piece and on your budget. Regardless of the type of coating, thicker coats are going to create a more durable final product, but this thicker coat will cost more in materials and will also add more weight. These kinds of factors must be considered so you know how much material is required to finish the job, and so you’re not left guessing during the actual spraying.

2. Detail
Does your finished project require a high degree of detail? If it does, you’ll want to ensure that you’ve exaggerated the depth of the foam carving to anticipate the thickness of the coating to be applied. Protective coating tends to smooth out details in the foam when it’s applied, so deeper sculpting will help avoid the loss of detail in the final piece. Once the piece has been coated, intricate details can still be added with the use of materials like epoxy putty, but anticipating this detail prior to coating will save some time when it comes to manual sculpting.

3. Texture
Depending on the final look and feel you want for your product, there are a number of application techniques you can use. Before you start spraying, know the technique you’re going to use and ensure that your work area is prepared for that particular technique. Perhaps your application technique will require you to stand at a certain distance from the piece, or maybe there are tricky areas that will require some creative spraying. Taking these types of things into account beforehand and planning ahead will help create a trouble-free application process, which translates into production efficiencies, less wasted material and a better end product.

4. Spraying environment
Even if you’ve considered everything you need to as far as technique goes, there are other external factors that can affect the quality of your coated piece. The environment in your spraying facility is one of these factors that can come back to bite you. When it comes to curing, some coatings can be fickle. Certain materials will not fully cure in an environment that’s too hot, cold or humid. In some cases, weaknesses in your product caused by improper curing might not even show up until after the piece has been installed. Be sure that you know what conditions your coating material needs to be applied in, and ensure that the surfaces to be sprayed are properly prepared to accept the coating. Without adequate preparation, bubbling, cracking and peeling may be the result.

5. Equipment readiness
Ensuring that your equipment is operating properly would seem to be a no-brainer, but it’s amazing how many projects run into serious problems thanks to misfiring equipment. Before every project, fully inspect your spraying equipment, checking all potential problem areas and running the required tests – including all health and safety considerations. Materials should also be inspected for proper mixing and temperatures. Don’t forget to cycle material through your lines periodically to keep the lines primed. While you’re spraying is not the time to find out that something is off, because at that point it’s probably too late.

Like most things in life, problems with foam coating application can happen when you least expect them. Operators that get used to equipment functioning perfectly over a period of time can get complacent, and it’s the one time when something isn’t checked properly that things go wrong. Unfortunately, things going wrong at the coating stage can mean the destruction of an entire project, so a little preparation goes a long way. With proper technique, training and preparation, your projects will be sure to impress.

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The office really needed a different kind of presence - so we thought we'd bring Yoda in to see what he could do. Our Yoda started as a small figurine. We scanned it using our 3D laser scanner and then created the enlargement on the FROGMill CNC router. What better way to illustrate the enlargement capabilities of our system by recreating one of the smallest characters from Star Wars. Anyhoo, it never hurts to have the force in your corner.
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Brian Cooley's work is about bringing the past to life - the results are often so realistic that all they seem to be missing is a heartbeat. Populating museums around the world and featured in National Geographic and the Discovery Channel, Cooley's life-sized dinosaur sculptures are world-renowned for their detail, accuracy and - most obviously - their scale. Automated foam carving is at the heart of Cooley's production process. By 3D scanning his original scale models and using CNC foam carving technology to enlarge the model, he is able to do away with much of the tedious enlargement work that used to bog down his process. The technology allows him to create a perfect foundation for his prehistoric masterpieces.

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The hard coating process is a critical step in the automated foam carving production process. As our most recent article explains, cutting corners at this stage can be disastrous. This means that you have to do your research when choosing the right coating material for the job - here are some of the most important considerations.

CHOOSING THE RIGHT HARD COATING MATERIAL FOR FOAM CARVING AND CUTTING PROJECTS

For many 3D foam cutting and carving applications, hard coating the foam is an integral step in the production process. Coatings not only provide the final product with strength and durability, but they’re also very important for the quality of its final appearance. Application methods are important, but don’t jump the gun. Before you go anywhere near your spraying equipment, it’s absolutely critical that you choose the right coating material for the job. We’re not just talking about finding the cheapest product, because that is often a recipe for disaster. Your choice could be the difference between a product that lasts and one that is quickly compromised by its environment. With many different coating products on the market, it can be a challenge to determine the ideal coating for the job. While there may be unique circumstances depending on the project, the following outlines some of the key factors that should be considered.

1. Environment
The nature of the environment your project will be exposed to is perhaps the most important factor in determining the choice of a coating material. If the project will live in a climate-controlled interior environment, you’ll be able to choose from a much wider range of coating products - most will hold up well in stable, moderate environments. It’s when things are taken outdoors that the potential problems can mount. Moisture, humidity, heat and cold will have different effects on different coatings and each can affect the integrity of your coated project. Throw in extreme weather or constant temperature fluctuations and the potential for damage is multiplied. With the wrong coatings, cracking, flaking and bubbling can result. By considering the main environmental elements at play and choosing a properly formulated coating, you’ll be able to avoid these kinds of failures. For exterior and extreme environments, pure polyurea coatings are often the best choice. Polyurea is UV resistant and also dimensionally stable in both very high and very low temperatures, so it will hold up well in most exterior environments.

2. Traffic and Handling
Whether inside or outside, the right coating material for your job will depend on how much traffic and handling your project is going to undergo. Is this a piece that will be completely out of reach? Will people be touching it? Will kids be climbing it? Is it a potential target of vandalism? If the piece will be subjected to a lot of this kind of traffic, you’ll have to choose a coating material that can handle the abuse. For very high traffic, a pure polyurea coating tends to offer the best protection, with hybrid and polyurethane products being good choices for lower traffic environments.

3. Texture
Your choice of coating will also depend on the kind of texture the final piece needs to have. If it’s smoothness you need, there are coatings that have longer cure times, which allows the material to settle for a longer period of time and create a smoother surface. There are also certain coatings that will cure harder and therefore offer better workability with air tools and conventional sanding processes. If your end product requires a textured surface, products with faster curing times are often useful for applying stippled coats. In considering the texture of the piece, you should also take standard viewing distances into account. For pieces that will only be viewed from afar, a slightly textured surface is often acceptable as viewers will not be able to see the details. It will also reduce the amount of surface sanding required compared to products that require a very smooth finish. If your end product requires a specific look, be it concrete, bark or skin, there are coatings that, when applied correctly, can create a more realistic look and feel.

4. Fire Rating
If your product needs to be fire-rated, this will impact your choice of coatings. You’ll find various coating products that come in both fire-rated and non-fire-rated versions. Note that the fire-rated versions will often be less dimensionally stable than their non-fire-rated cousins.

While this is not a comprehensive list, these considerations are a good starting point for narrowing down your coating choices for foam carving and cutting projects. It is important to note that there are trade-offs across the various products. Fire-rated coatings might be less dimensionally stable. Hard coatings that are easily sanded may not be recommended for extreme weather or durability requirements. Stronger polyurea coatings tend to be more costly. You’ll have to find the right mix of qualities to match your particular requirements. The bottom line, however, is that the coating stage is not the time to cut corners. Projects that have taken countless hours to get to the coating stage can be swiftly destroyed with the wrong kind of coating. Make sure you get it right the first time – because second chances will be costly.

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Over the past few months, FROG3D® has done its fair share of world traveling. With recent installs in Columbia, Turkey, Lebanon and England, it looks like our frog's plans for world domination are coming to fruition. Who knew frogs could be so ambitious?

Given FROG3D®'s hectic travel schedule, our technical staff have taken on the dual role of installing and chaperoning the system as it makes its way around the world.  Over the coming months, we'll follow their adventures in a blog feature that we'll call Travels with FROG3D® (that's all I could come up with right now - sorry). Stay tuned. Read more