Rapid prototyping of a car body with the 3D-CNC milling machine RaptorX-SL made of styrofoam. We mill with a very special Styrofoam cutter (diameter 20 mm and length 150 mm) made of steel. The depth infeed during roughing was selected here to be 140 mm, the distance between the milling paths is 5 mm, for finishing 1.5 mm.
Of course, the milling paths were generated by the software ConstruCAM-3D.
The feed speed is 100 mm per second, 6 meters per minute. The complete form with a size of approx. 600 x 450 x 140mm was completed in only approx. 15 minutes. In these materials, one could, for the sake of saving time, forego the pre-milling and finish the workpiece directly with a small distance between the tracks.
With the special milling cutter used and the high feed speeds, we got a clean and for the material quite smooth surface, which comes very close to a hot wire cut.
There are special lacquers or roll coatable and sprayable two-component coatings for the surface treatment of Styrofoam, which make these materials shine even in high-gloss colors and, above all, are even weatherproof. This makes Styrofoam the ideal material for trade fair construction, mold construction, large-scale construction, etc.