Pros: It gets the job done.

Cons: Inexperienced individuals generally produce an unprofessional looking job. Blocks tend to break off due to insufficient adhesive or aging of substandard adhesive.

CNC ROUTER / MILL
A CNC router cuts / mills the foam to yield a foam insert with comprehensive complexity. The cut foam layers are then laminated to assemble the complete insert. Total control over cavity shape and depth is achieved with this method. Ideal for small to moderate quantity (up to 500) applications, this method yields high aesthetics and precision repeatability.

Pros: Ability to cut complex geometry - precise shapes and depth
Guaranteed repeatable results with high aesthetics

Cons: Non-Recurring-Engineering (NRE) and setup charges are applicable.

CNC WATERJET
A CNC controlled nozzle directs a fine bead of high pressure water to cut the foam. The cut is
straight through and thus the machine has no control over cavity depth. Cavity depth is achieved
by removing the block (cut by the waterjet), trimming and reinserting it into in the cavity. The cut
foam layers are then laminated to assemble the complete insert. Ideal for small to moderate quantity (up to 500) applications, this method yields high aesthetics and precision repeatability.

Pros: Ability to cut complex geometry - precise shapes (not depth)
Guaranteed repeatable results with high aesthetics

Cons: Non-Recurring-Engineering (NRE) and setup charges are applicable.

DIE STAMPING
Foam layers are cut with a steel rule die then laminated together. The cut is straight through and thus there is no control over cavity depth. Cavity depth is achieved by removing the block (cut out by the die), trimming it and reinserting in in the cavity. The cavity walls will have a concave profile with each foam layer resulting in an unappealing “ribbed” effect. Ideal for large quantity (over 500) applications, this method is “tried and true” for large scale production.

Pros: The most effective and economical approach for high volume production requirements.

Cons: Non-Recurring-Engineering (NRE), tooling and setup charges are applicable.
Design changes result in substantial tooling charges and lead times.