CNC and Modeling Foam (Rigid Polyurethane Foam) - Low Density 6lb/ft3

Low Density R40 CNC and Modeling Foam by Duna

Our foam is perfect for 3D models with intricate shapes and layers using a CNC or hand shaping. It is hard to find in small sizes (our starting size is 12” x 12”when you would normally have to buy at least 4' x 4' or larger). It is dust-free, easy to sand and paint and more durable and attractive than Home Depot insulation foam. 

CORAFOAM® Low density polyurethane and polyisocyanurate foams are rigid foams mainly used with thermal insulating purposes, thanks to their low thermal conductivity values and their high insulating power. 

CORAFOAM R-series Polyisocyanurate Foam is a new series of Prop Foam developed specifically for the carving industry. This new product line includes Prop Foams dedicated to set and stage design or scenery. CORAFOAM® Prop Foam is specifically designed for the scenic, theming and film industries. Thanks to its desirable properties, Prop Foam is suitable for applications requiring strength and a higher level of detail not achievable with styrene. Prop Foam can be easily carved by both machine or hand (but not hot wire), making it a versatile product for sculpting.

The density of our PIR/PUR low density foams runs from 15 to 60 kg/m³. Different families of foams are available, according to the special requirements of the specific application, (e.g. fire behavior)

Prop building material with excellent carving/customization properties to allow set scenographers/project managers freedom to design highly accurate, stable creations. For high level props to be built, DUNA-USA foam has these main features:

• Grain-free consistency, making Prop Foam easy to carve with hand/woodworking tools;
• Bonding Prop Foam blocks together is easy and allows for production of large scale props;
• Prop Foam is still lightweight, even with its high strength
• CORAFOAM® Prop Foam is compatible with most coatings, which makes it easy to meet design requirements;
• Prop Foam is non toxic (dust mask still recommended);
• Closed-cell, will not absorb water

As a versatile, high-performance material, Prop Foam enables designers to create props for several applications:

• Foam Props: Prop Foam is perfect for creating props of different sizes and shapes. Prop Foam is also compatible with almost any type of coatings making the possibilities limitless.
• Set Design: With Prop Foam, you can easily sculpt stage props and scenery. Prop Foam’s large sheet sizes make it easy to product large-scale scenic elements, from a single block of foam or by bonding multiple blocks together.
• Large-scale Characters: Large blocks of Prop Foam are easy to move and fabricate. Animals and antique statue replicas can be easily fabricated and transported, with greater strength than typical styrene products.
• Molds and Plugs: Prop Foam can be used as a vacuum form plug. Mold making with R-series Prop Foam lets you recreate a perfect copy of any original subject.
• Museum Exhibits: Foam Props represent a valuable tool when it comes to recreating scenery or temporary stages for museum exhibits.
• Sculpting Foam: With Prop Foam, it is easy to create complex shapes and carve highly detailed sculptures.
• Prop Building: Foam can be used as a prop material or it can support the prop building process. 

PRODUCT VIDEO:

MILLING:

CORAFOAM® can be cut with anything that can cut wood, including CNC machines, standard woodworking tools, and waterjet cutters. Its closed cellular structure and absence of fibers or granular structure result in crisp, excellently defined edges after fabrication. The heart in the photo was cut with a kitchen knife and sanded so you can make beautiful objects easier than with wood.

It is also impermeable by any type of liquid, including water and solvents, making it much better suited for severe weather conditions or harsh marine environments than many other materials.

Almost any type of adhesive can be used to bond CORAFOAM®. Because it is a polyurethane foam, polyurethane adhesives such as DUNABOND work extremely well, but it is also possible to use epoxies and other types of adhesive

Due to its ultra-smooth surface, CORAFOAM® is compatible with almost any type of primer or paint. Generally, it is easiest to use a highbuild (primer with high solid content) with CORAFOAM®, but it is not mandatory. Any high-quality exterior grade primer will work with CORAFOAM®.

The most “bulletproof” method of attaching fasteners to CORAFOAM® is to drill a hole that is slightly wider and deeper than the fastener, fill it with epoxy or polyurethane resin, set the fastener in and let it cure.

Due to its grain-free structure, in many situations it is recommended to reinforce CORAFOAM® by using a backer or adding reinforcement in strategic areas, or by building a frame.

NOTE: This is rigid foam, not suitable for cushioning. 

SPECIFICATIONS

• Low Density (LD) - R Series - R40
• 4 lb/ft³ 
• Tan color
• Interior and exterior usage
• Will produce chips instead of dust when cut on CNC. 
• Grain free consistency
• Ultra smooth surface makes for easier finishing
• Can be fabricated with anything that can cut wood.
• Closed-cell, will not absorb water.
• Can be easily made to look like wood.

APPLICATIONS

• Sign Making
• Prop Making
• Core - Material
• Prop and Set Design
• Wood replacement for architectural elements
• Thermoforming master models
• Composite layup tools