How to Cut Foam

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JohnGrimsmo

JohnGrimsmo

Күн бұрын

This video may be a little longer, but you will learn everything that has went into the process of making our foam cases what they are today. Now, every knife comes with a foam insert, which the brothers Grimsmo design and mill themselves, and a hard plastic case.
John also came up with 2 general tricks that will help anyone with cutting foam!
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Datron Tool's foam cutting end mill: www.datron.com/tools/foam-cutting-tools.php
Foam Fit Tools: www.FoamFitTools.com/
Music from: www.EpidemicSound.com

Пікірлер: 492
@maartenscholtes4117
@maartenscholtes4117 5 жыл бұрын
Hi. I work at a flight case company in Holland where I cut a lot of foam for huge flight cases to tiny presenting boxes like yours. So I thought you might like some tips. How we do it. Instead of putting the foam directly onto the suction grid we put a thin sheat of 3 millimeter mdf wood that allows the suction to go tru and then set the dept of the router to just hit the mdf so you cut al the way tru the foam. So then you get an instand smooth edge. I do like you're idea of the table router to round of the edges. Nice! We use a very fine bandsaw that you can put on a 45 degree angle. But I think you're doing it well! When the foam comes of the cnc it's always a little bit rough, that normal. So we hit it gently with a heat gun so it melts all the burs away and gives it a general smooth finish. Another thing, my personal taste, I think it looks a lot better If the egg box foam in the lid has smaller bumps. Here in Holland you can get them in all sorts of depths en thicknesses. Good luck!
@psfanboy79
@psfanboy79 6 ай бұрын
Genius, so many great ideas/improvements in the processes
@qianbao-epefoammachine8184
@qianbao-epefoammachine8184 7 күн бұрын
I have a more effective way to cut foam😊
@nickattac
@nickattac 6 жыл бұрын
A trick for getting rid of the fuzzy edge is to use a heat gun. The tiny fuzz shrinks from the heat faster than the solid foam will burn. So if you do it quick enough you get a clean product.
@jamesmaccubbin7434
@jamesmaccubbin7434 3 жыл бұрын
If you are this thoughtful about your foam packaging, I can't imagine how AMAZING your knives must be!
@peterpherfinion6671
@peterpherfinion6671 6 жыл бұрын
I spent 40 years in the machine tool industry John and you did a great job with that foam insert. I had several ideas pop up during the video only to see you use them later in your presentation, so "great minds", eh? All in all, nicely done and it was fun watching the problem solving process again.
@nicholasdavis8159
@nicholasdavis8159 6 жыл бұрын
Man the attention to detail you guys put into this is phenomenal. Your passion really shows. You guys will be very successful
@tiger182281
@tiger182281 6 жыл бұрын
From experience, if you go over eva foam lightly with a heat gun it helps clean up some of the fuzz around edges. Not sure if it'd work with that foam but might be worth a shot on a scrap piece.
@minibigs5259
@minibigs5259 6 жыл бұрын
#CosPlaySecrets :D
@MrLiamCooley
@MrLiamCooley 6 жыл бұрын
Yea Ive done this! Hit it quickly with the tip of a bic
@mrcokez1
@mrcokez1 4 жыл бұрын
" How to Cut Foam " Step 1: get foam Step 2: get a $5,000 milling machine Me: LOL
@greebo7857
@greebo7857 4 жыл бұрын
Don't forget the CNC software and the time to design the layouts.
@MetalMayhem1978
@MetalMayhem1978 4 жыл бұрын
Only $5K ?
@judicar
@judicar 4 жыл бұрын
CNC is really just a fancy motion system for a trim router with an end mill.
@CulbableJimmy
@CulbableJimmy 3 жыл бұрын
Haha lmao exactly
@randybobandy9828
@randybobandy9828 3 жыл бұрын
@@judicar no it's not.
@marang1966
@marang1966 2 жыл бұрын
Attention to detail even on the small things mean a lot to the customer. Great job!
@michaelmeisman4731
@michaelmeisman4731 6 жыл бұрын
I have been CNCing foam for years. I assure you that trimming the outer edge of the hole first is what we have been doing for years. With foam working from the inside out almost always works better. We have used a curved razor as well as routers to make radius edges. All in all very good job with a nice learning curve.
@jordancox1102
@jordancox1102 6 жыл бұрын
As an Entrepreneur myself, I really appreciate your attention to detail and dedication to improving the quality of your packaging. To be honest, I had never heard of your company before today when this video showed up in my suggested videos. I'm definitely going to be looking into your products, as I am also a knife enthusiast! Keep up the great work and never stop striving to put out high quality stuff!
@JohnGrimsmo
@JohnGrimsmo 6 жыл бұрын
Awesome Jordan, thanks for watching!
@patrickyao9051
@patrickyao9051 4 жыл бұрын
I just spent 16 minutes watching foam cutting. And it was awesome.
@arcnline360
@arcnline360 6 жыл бұрын
You guys are too much, the attention to detail is amazing. Good job! Now I want one of your knives.
@HunGredy
@HunGredy 5 жыл бұрын
Wow, everyone bashing about milling the foam yet nobody seems to care about the enthusiasm this guy talks about his work and the product... I smiled through the whole video thinking how happy I would be to work like him, being inventive about methods and then enjoying the result. You sir, made me want to buy a desktop CNC machine and make custom multi-layered foam for toolmen. Although I could probably accomplish that with my trusty Dremel, just need that Datron bit. I also understand that if you already have a milling machine, why the heck spend money on custom tools just to cut instead of milling when it's already available and doesn't need you to be there, working alone? I work in a small metal workshop and we many times have to go with what we have, not buying custom tools for one job. I liked this video a lot. Just ordered some samples from ShadowFoam by the way, being in Europe.
@skycorrigan6511
@skycorrigan6511 4 жыл бұрын
I love that you guys make EV-ERY-THING! Truly special
@jodiloufoundation7890
@jodiloufoundation7890 6 жыл бұрын
Hi John, You can cut all the way through the product if you use a 5/32 piece of hard board with a flat closed cell (Adhesive backed) foam on it. You then can suck that down to the vacuum table and cut shallow pockets that follow the general shape of the part with just a little offset. These smaller pockets would essentially combine to form the shape of a part which you then create the array from. This forms a seamless, flat, gasket surface that will not leak. Ports are added to the jig to allow vacuum pressure to build in each pocket section. Then, you just suck down the template and your raw material at the same time. Here is the ultimate trick that makes this work. Since you now have a thickness to the foam that resides on the top of the template (bottom of the case foam), you can now cut all the way through the case foam without releasing the part as long as you only cut into the template foam but not through it. We used this method all the time and it is awesome. it would look similar to the jig set up in the link provided, but your cutter would not go all the way through the foam in the cut path below the part. This company sells the sheet goods. allstaradhesives.com/cart/category/cover_sheets
@bobyca2003
@bobyca2003 Ай бұрын
is a very dinamic and realistic video ... is amazing!
@doughall1794
@doughall1794 6 жыл бұрын
Thank you for sharing your process of solving your problem and enjoy the commitment to your quality standard.
@JohnGrimsmo
@JohnGrimsmo 6 жыл бұрын
Thanks for watching and enjoying Doug!
@foesfly3047
@foesfly3047 3 жыл бұрын
I'm impressed with your process problem-solving skill. I wouldn't have considered changing tool paths to correct the edge cutting issue. Since the material in use is just foam, I THINK it might be much less costly to cut using custom dies for each layer, before bonding them as a final sandwich/assembly. Instead of wearing out an expensive CNC router that requires several minutes per unit... a custom cutting die would simply press down and through the foam in 2 seconds. A medium durometer rummer base surface would preserve the cutting edges forever (virtually). I don't want to sound critical. Your business and presentation/marketing skills are exceptional. Thanks for posting.
@StangspringDK
@StangspringDK 6 жыл бұрын
Hot damn, these foam inserts are awesome. Lot’s of useful tips for anyone wanting to cut foam on the CNC.
@kitingmare
@kitingmare 6 жыл бұрын
I had an idea for the back radius: A screen for the vacuum plate to put the foam inserts back on it upside down and milling the big radius on the CNC. Picture a lasercut plastic/acrylic/wood/thin aluminium "waste" lattice from your parts. With the screen you locate the inserts to the plate and cover up the exposed bits at the same time. This way you can even mill a small pocked if you need more space for things in the bottom.
@7sushi4fushiyogo
@7sushi4fushiyogo 6 жыл бұрын
I remember when you used to ship your knives wrapped in newspaper. You've come a long way since then.
@PetesShredder
@PetesShredder 6 жыл бұрын
I use a 20w fibre laser to mark foam like that, and it comes out really well. Just melts the surface, very clean high resolution mark in only a few seconds (along with some nasty smoke.) I use plastizote LD45 or thereabouts for the foam, routed and then laser marked to put the logos on. its so fast, we even engrave customers names on their foam as we send stuff out. Takes seconds.
@cschwad559
@cschwad559 6 жыл бұрын
Just a thought, John. I totally thought at the beginning conventional milling would do the trick and was pleased ro see that's what you discovered. Another idea, why don't you machine a brand for your logo to heat stamp into the corner? Would save you tons of time on the mill.
@waadgaad2024
@waadgaad2024 Жыл бұрын
I'm starting to carve cross link polyethylene foam, everything he's said has been correct so far. Great results so far!
@inspectorsteve2287
@inspectorsteve2287 5 жыл бұрын
This type of foam works great for tool boxes. Making spots for every tool
@scottdunlap4109
@scottdunlap4109 2 жыл бұрын
What kind of foam is that on the bottom?
@inspectorsteve2287
@inspectorsteve2287 2 жыл бұрын
@@scottdunlap4109 I'm not sure of the name. You can find it on Amazon just search tool organizer foam sheets.
@JCisHere778
@JCisHere778 6 жыл бұрын
Maybe you should make a aluminum/ Plastic template that fits inside the foam cutouts, on which the router bearing could ride. I think it would make Berry's job a little bit easier and more consistent. Regards from germany
@danielrose1392
@danielrose1392 6 жыл бұрын
Great idea. I would try a frame enclosing the upper half of the foam combined with an undersized bearing to end up with proper final dimensions.
@cajunsurvivor
@cajunsurvivor 6 жыл бұрын
Exactly my thoughts.
@FUBAR956
@FUBAR956 5 жыл бұрын
Ooooor make a die from steel die rule and use a clicker press.
@shadowliving6858
@shadowliving6858 5 жыл бұрын
I enjoy your full explanations of your thought process and then watch as you put it into action. Well done.
@OptikDojo
@OptikDojo 4 жыл бұрын
SO funny! Here I am looking up DIY foam cutting for fishing project and this video pops up from my grail maker. I don't have the tools Grimsmo has but hey, Im watched the whole thing any way. Good to see you guys! Beautiful work all the way around. Your attention to detials in every aspect demonstrate the pinacle of craftsmanship.
@TrogdorBurnin8or
@TrogdorBurnin8or 6 жыл бұрын
In re: "Make chips" - I don't know the details of your plastic foam, but in some cases you can make soft materials like this more brittle by keeping them in the freezer until you need to machine them, or by some kind of forced air or wet process at the bit to keep them from melting by tooling friction.
@dennygreen3369
@dennygreen3369 3 жыл бұрын
amazing on how much time and work that even go into just the case you obviously are a perfectionist and it shows in the quality of your knives .... don't own one yet but have handled a Norseman and fell in love! Keep up the great work John and team.
@bearsrodshop7067
@bearsrodshop7067 3 жыл бұрын
25+ doing custom interiors,,and still using a DA with 60grit 3in flex wheel,,,Router use was a super means of removal,,love it,,nice to see you putting should detail into the cases,,Bear
@wadopotato33
@wadopotato33 2 жыл бұрын
When you form dense foam buttstocks for guns you grind them on a belt sander to get the final shape. However they tend to struggle because the friction makes them too hot. Try putting your foam into the freezer before you use the roundover bit on them. I bet that will make the roundover easier and cleaner. The cold will make the foam more ridgid during the roundover process. Worth a try and is the go to trick for ridgid foam grind to fit shotgun recoil pads.
@stevebray71
@stevebray71 6 жыл бұрын
Love the cases found video on a recommended. To put the labels on the cases to help you keep them straight you need to make a jig that will help you with the alignment and to keep them from going on wonky. Hope this helps u looking forward to seeing some of your other different videos 👌👍🤗
@ricvis44
@ricvis44 6 жыл бұрын
Holy crap! Such attention to detail. Great tips and great vid! Well done!
@SelfMadeProject
@SelfMadeProject 6 жыл бұрын
Glad the videos are back! Great job Erin!
@JohnGrimsmo
@JohnGrimsmo 6 жыл бұрын
:-)
@lwilton
@lwilton 6 жыл бұрын
Should be able to use wood router bits in your mill. Quarter inch radius corner rounding bit with no bearing, run it like an endmill. Only trick might be fixturing and holding the foam after you finish the top and flip it upside down. Might be able to make a fixture plate that will sit on your vacuum plate and direct the vacuum to the right places to hold the individual pads once the router bit cuts them up.
@Mrcaffinebean
@Mrcaffinebean 6 жыл бұрын
l wilton I concur, just stop, flip, change tools and bam, perfect every time.
@393strokedcoupe
@393strokedcoupe 6 жыл бұрын
Great work on the foam John. I have a suggestion that may have cleaner and safer results when routing the radius. Machine a jig that fits over the foam, just the upper half and put a smaller bearing on the bit and presto, clean, precise and no accidental radiuses on fingertips.
@josuelservin2409
@josuelservin2409 6 жыл бұрын
393stroker, Great idea!
@TurpInTexas
@TurpInTexas 5 жыл бұрын
Thanks for sharing your videos. I'm sure you have given lots of people the courage to become an entrepreneur since you fill in a lot of the mystery of all the steps it takes to run a small business. Since you have the equipment to make a mold, have you thought about just creating the exact piece through injection molding? Of course you would have to learn how to mix the chemicals to make the foam, but it would give you a nice smooth surface finish, and it would give you even more control over the process.
@laneveach9317
@laneveach9317 6 жыл бұрын
Love the iterative design process for your cases. They look awesome!
@AmorCNCLaser
@AmorCNCLaser 4 жыл бұрын
Good video and good job! For the thin and small foam cutting,milling machine is suitable. Also good at engraving on the foam.
@georgemacdonald5282
@georgemacdonald5282 2 жыл бұрын
Great video, closest yet to getting perfect sides on foam
@skyerenard8939
@skyerenard8939 6 жыл бұрын
I just stumbled on you guys cause of this video alone. I now want one of your knives
@serdaraytemiz
@serdaraytemiz 5 жыл бұрын
I just saw this video. Awesome. I highly suggest you watch (albeit totally different subject) the following channels about working with foam. Kamui Cosplay and PunishedProps. I highly suggest trying the heatgun method for heat sealing and deburring the foam... I always though about laser cutting the layers and glueing them later. So thanks for sharing. Cheers.
@kill3rkitt3ns
@kill3rkitt3ns 6 жыл бұрын
Really cool to see how much time and attention you put into even smallest of details 😀
@JohnGrimsmo
@JohnGrimsmo 6 жыл бұрын
You bet! Everything matters.
@LucasHartmann
@LucasHartmann 6 жыл бұрын
You can use the big cnc to make a mdf support, fit the foam in the support so it stays firm, then use the table router with the roundover bearing indexed on the mdf.
@eduki
@eduki Жыл бұрын
I decided finally to buy my own foam cutting company to make room for my cheap tools storage PVC briefcase. Thanks!
@DEFINITIVEPENCHANT
@DEFINITIVEPENCHANT 6 жыл бұрын
John, adaptive clearing is ALWAYS the answer.
@f1pitpass
@f1pitpass 3 жыл бұрын
love the development stages and thank you for all the tips!
@jerrywhidby5259
@jerrywhidby5259 6 жыл бұрын
At the beginning I was saying "No CNC, no CNC", and then "Crap!". Apparently everyone but me has a CNC machine, lathe, and a 3D printer.
@robr3015
@robr3015 5 жыл бұрын
Damnit Jerry I thought there was a hair on my monitor! :D
@randybobandy9828
@randybobandy9828 3 жыл бұрын
Atleast get the 3d printer...they are as little as $130 for a decent one.
@MaximilianonMars
@MaximilianonMars 3 жыл бұрын
Yeah as the other dude said, 3D printers are not prohibitively expensive. The software to design (such as Fusion 360 non-commercial license) and slice your files is free, many free models online also. Material is fairly cheap
@wilfredbao9998
@wilfredbao9998 6 жыл бұрын
The sticker looks great!
@spunkysandoval
@spunkysandoval 6 жыл бұрын
You guys have come so far. Some day, I will buy a Grimsmo.
@samuelirons5548
@samuelirons5548 6 жыл бұрын
Thanks for this John. Time to do the toolbox drawers. Myself that is
@noisyaudio
@noisyaudio 6 жыл бұрын
The round over router bit has a bearing that needs a hard surface to follow. Make a insert that mates to the foam cut out but offers a smooth hard outline surface for the bearing to profile.
@arinehim
@arinehim Жыл бұрын
I have the exact same foam in my toolbox. Its cut specifically for my set of craftsman ratchets and sockets
@TheCrash8212
@TheCrash8212 4 жыл бұрын
Ever looked into die cutting? It's FAST and CLEAN. Die cut the top then glue the color pad layer and die cut the outside. Emblem could be heat stamped in less than a second.
@skippyman22
@skippyman22 6 жыл бұрын
Thanks for all the videos John!
@JohnGrimsmo
@JohnGrimsmo 6 жыл бұрын
You're welcome!
@anger42
@anger42 Жыл бұрын
Start with a thin piece of black foam and stamp your design out with cutters...then glue the thin piece to the bottom. DONE!!!
@ronfuller235
@ronfuller235 4 жыл бұрын
Very much enjoyed your video
@joejones6120
@joejones6120 6 жыл бұрын
Looks cool. Only suggestion I could make that would help your throughput and may assist with your router table, is to use a profile cutter to remove your foam from your blank. Basically a razor sharp cookie cutter. Light press around each perimeter and you no longer have the remnants to work around for the bearing. Or you could use a 3m strip on the base or edge of the vacuum holes to hold the pieces to the table and then remove the material you leave. Really cool either way.
@UncleManuel
@UncleManuel 6 жыл бұрын
Now that's a ton of useful information right there! Thanks for sharing your experiences and solutions.. :-)
@thehamlinwoodshop
@thehamlinwoodshop 6 жыл бұрын
Love your attention to detail. I always look forward to your videos!!
@JohnGrimsmo
@JohnGrimsmo 6 жыл бұрын
Great to hear! Lots more in the pipeline.
@hfranke07
@hfranke07 6 жыл бұрын
Have you considered to cast the foam parts? Smooth-On has lots of different types of foam, that would fit your needs. This way you could cast the foam parts in ONE go. If your mould is big enough for 6 pads, you could make 6 pads in less than 5 minutes. Nice video btw. Thanks.
@astbrnrd
@astbrnrd 6 жыл бұрын
Dang John... You & Erick are missed. I get it though, you really are making things happen. Proud of what y'all have achieved.
@JohnGrimsmo
@JohnGrimsmo 6 жыл бұрын
Thanks bro! We've been here all along, just hidden in the shop working away hahaha
@hardcry4159
@hardcry4159 6 жыл бұрын
Hey John, you might want to look into a straight flute endmill instead of spirals. I use to cut plastics and wood with spiral endmills but they leave rough burred edges. With a straight flute, you should get clean pristine edges on foam all day!
@davidparker3346
@davidparker3346 2 жыл бұрын
I love your attention to detail even on the foam inserts. Vacuum works great , I was wondering how you held it down. Like how you share your secrets.
@HughesEarthworks
@HughesEarthworks 6 жыл бұрын
Very nice John! I really enjoy the process.
@DanRich01
@DanRich01 5 жыл бұрын
Thanks, very nice work, its interesting how you guys tweek the finer details like on the woodworking table router and manual milling techniques instead of cnc climb milling.
@repalmore
@repalmore 6 жыл бұрын
John, look into what's called a pin router. It will cut the same pattern every time. Make a pocket for the foam to fit in and then you can rout the the edge the same every time.
@matthewdunstone4431
@matthewdunstone4431 5 жыл бұрын
Thank you for sharing this content. Five stars.
@hacklabdesign
@hacklabdesign 6 жыл бұрын
Nice work John
@CygnusRising
@CygnusRising 6 жыл бұрын
#BecauseGrimsmo moments watching this video: - Plastic decal stickers? Why not laser-etched aluminum? - Space in the bottom of the case for the sticker and the card? Why not a super-fancy CoA instead of just a business card? I can totally see a Grimsmo logo-embossed CoA. Maybe I'm crazy... - Why not a router table with a roun -- Oh, good, they thought of that. I would say that getting a smaller CNC for just the foam isn't wholly a bad idea -- looking at that cleanup after doing a few pallets and I can't imagine how much of a mess it would be if it's not spotless before going back to the titanium when the flood coolant comes in. None of this is criticism, I am continually staggered by your not just continuous, but relentless improvement. Keep up the amazing work, and never settle for less, it's why I enjoy watching you guys work. Maybe if the stars align, some day I'll be able to have a Grimsmo of my own.
@JohnGrimsmo
@JohnGrimsmo 6 жыл бұрын
Thanks Peter! Great ideas indeed. I have definitely thought about laser etched decals and COA cards, but man, I'm just not ready to buy a laser yet. Plus I really like that our cards are still hand signed by Erik and I, adds a level of personality to it. Maybe we'll change them up down the road. A dedicated small CNC is on my mind for sure, but I don't know when it would happen. For now, roll with what works! Then improve when we can.
@CygnusRising
@CygnusRising 6 жыл бұрын
You could still sign every COA by hand, but I agree, that's indicative of the personal, hand touch attention to every single little detail that's a hallmark of your brand -- way more important than having it be fancy in other ways. A hand-signed Post-It note would be more aligned with that than a fancy but impersonal CoA, for sure. At least the barrier to owning a laser is a lot lower than it used to be, and I imagine that even the smallest Tormach or the like (XCarve?) would be sufficient for the foam, but I'm sure space is a huge premium in the shop, even for machines as 'small' as the size of a laser and CNC that would fit those needs. I definitely am enjoying the increased content coming to your KZfaq channel as of late, and I hope that it makes enough business sense to keep it up long-term.
@TheSnakebite03
@TheSnakebite03 2 жыл бұрын
Can also get rid of fuzzy edges going clockwise and counterclockwise on the outside cut. That’s what I usually do if I see on side is clean and the opposite side isn’t
@kenmarsh
@kenmarsh 4 жыл бұрын
Excellent job!
@MikeHermesPhotography
@MikeHermesPhotography 5 жыл бұрын
Sounds like Eric deserves a raise
@ciscogsx1000
@ciscogsx1000 6 жыл бұрын
I loved the look of your logo on the top foam. Heres a thought. A little dab of adhesive on the tips of the egg carton foam and the foam put in wavy side facing the case top. This will glue it so it wont fall out. Your logo on the flat side so you can see it or on a thin piece of denser foam adhesived to the flat side of the wavy foam. All this should give you a springy top foam that will hold everything snug when the case is shut and still have that super bad ass look of your logo on the top foam. Just a thought. Hope it makes your product better.
@SteveLoves2Fly
@SteveLoves2Fly 5 жыл бұрын
This is where having a good vendor makes the difference. This is a lot of time and effort put into packaging. This time and effort could be spent on marketing or making new products.
@cyrex686
@cyrex686 6 жыл бұрын
If you want to know the proper way to do this that industy uses, lookup "steel rule die." They are mostly used by the cardboard industry, but are great at cutting foam/rubber consistently, quickly, precisely. At the place I used to make them we charged about $500 for a basic one. You can buy the steel rule and make one yourself by bending it and hammering it into slots cut in plywood.
@mattinkel7342
@mattinkel7342 6 жыл бұрын
Those injection moulded snap cases look awesome, a real pet hate of mine is the cheap all in one blow moulded cases that fold over a piece of plastic as the hinge.. I hate them with a passion they always split and break .. I like real sturdy hinges! Foam work is looking crisp! .. I cnced veg tan tooling leather for the first time a couple of months back.. works great!
@andresaristi5646
@andresaristi5646 6 жыл бұрын
Love how you share the knowledge
@JohnGrimsmo
@JohnGrimsmo 6 жыл бұрын
Thanks Andres, I've always found it really fun and rewarding to share what I'm working on.
@jasonsapp4096
@jasonsapp4096 6 жыл бұрын
Hey John, My thoughts on the foam Radius. Machine a positive die/male. this way the foam could be turned over and the die used as a template/pattern routing system. With a custom router Bit (lets say lakeshore), bearing on the bottom to follow the template, foam upside down on the template. This could face the edge and round over the radius. Please get your man a pair push block.
@erikpecchi7462
@erikpecchi7462 6 жыл бұрын
Wow when i was watching the video,I could not believe you were milling the foam,I could see if you needed a one off item,but i was like screaming as i was watching more and more just thing why are they not Die cutting them,it is super easy to do Basically you just bend up thin spring steel called Die Rule,and you just insert them into a MDF pattern of your shape and use a Arbor Press or a Rubber Mallet to hit around the Parameter very simple,then you can use 3M contact adhesive to laminate the two different colors together
@FUBAR956
@FUBAR956 5 жыл бұрын
erik pecchi with a die they’d need a clicker press. Quicker than milking them out.
@harrelsontrumpets
@harrelsontrumpets 4 жыл бұрын
We used to mill ours as well because you need varying depths, which not easily achieved with die cutting processes. Now we use a laser to cut and glue the layers together, which is still labor intensive.
@tonedizzle6289
@tonedizzle6289 5 жыл бұрын
You *might* be able to remove the router table step all together with a back corner rounding end mill. Use the thumb indent for entry/exit location and then just go for it full engagement. Lots of reasons this might be a total disaster and would definitely not work in materials that aren't foam but who knows, might save time and give you control over that last step. Really cool video btw.
@MrMoffett82
@MrMoffett82 Жыл бұрын
Don't know if it's been mentioned and it's only an idea but instead of the round over bit for the outside, have a template and a flush trim bit
@danielrose1392
@danielrose1392 6 жыл бұрын
To avoid loosing suction, but being able to cut through, you could create your own vacuum pattern. Place grooves like your original table has where your final pieces will be, but don't place any grooves under the cuts. This way you won't break the seal making the cuts.
@jackflash6377
@jackflash6377 6 жыл бұрын
Very, Very informative video. Thanks guys.
@davidschnabel5026
@davidschnabel5026 5 жыл бұрын
For such a beautiful knife you should have a walnut box with brass hinges, no plastic or foam.
@manuelbou2576
@manuelbou2576 3 жыл бұрын
For the table router setup, make a jig for the foam to insert in and then you can pass the jig around the router bit. Hard to explain in text but hopefully that could help
@lainethm
@lainethm 6 жыл бұрын
Cool video, greetings from Finland
@unpopular_mechanics
@unpopular_mechanics 6 жыл бұрын
You could cnc or route a zero clearance plate for the router table fence, that would allow you to push the foam up against the face of the fence rather than just a small bearing.
@keithviolette5870
@keithviolette5870 6 жыл бұрын
One more tweak to your process would allow you to complete the edges and underside chamfers in one setup. Make a custom vacuum Chuck with 6 raised chuck platforms slightly smaller than each foam insert. The height of the platforms should be at least 1.5 X the foam thickness. When you cut the perimeter of all 6 inserts, the scrap will fall below the bottom of the inserts. Now you can use a dovetail cutter to finish the underside chamfers. Turn off the vacuum, and you have 6 finished parts.
@bob505470
@bob505470 6 жыл бұрын
might be time to pick up a cnc router. much better suited for foam cutting imo. The ability to have a dust shoe on cnc routers is amazing for cleanup.
@adambergendorff2702
@adambergendorff2702 3 жыл бұрын
I know its 2 yrs old, but great video, Thanks
@frollard
@frollard 6 жыл бұрын
At our makerspace we really love using a laser cutter on foam like this - but we wouldn't be able to do the dual layer like that without manually gluing it after the fact. (cut stencil then glue to solid base) Laser foam is awesome. Looks like you tweaked this to perfection too :D
@azwelke2638
@azwelke2638 3 жыл бұрын
Nice containers!!
@ptick16
@ptick16 Жыл бұрын
I'm curious as to why you wouldn't want to use laser cutters, as opposed to the carbide engraving tools that you're currently using? Lasers are so much more precise, and they are economically priced too. Lasers will also provide a much tighter fit inside the case, along with cleaner lines on the cut. Still, I admire how passionate you appear to be with the creative solutions that you've come up with for your product(s).
@poopagore
@poopagore 3 жыл бұрын
at 4:28 that knifes wood inlay looks sick. I just made my first custom grimsmo. I'm so fucking excited to get it
@bwdiver1
@bwdiver1 4 жыл бұрын
Glad you put such detail in your boxing but the egg crate on the top lid is plain cheap looking. Like the first design much better, looks high end. Hope you put that much thought in the knives. Need to try one I guess.
@constantinosschinas4503
@constantinosschinas4503 5 жыл бұрын
support/press the foam with a wood plate when routing/rounding edges. this way it will stay rigid and flat for consistent finish. plate can have a handle if handy.
@szki272
@szki272 6 жыл бұрын
I have never machined foam but my first thought is. For the bottom consider making a cap that locates off your cuts in the foam or the outside. Then use a router table with a radius bit. The cap is for the bearing to run on. Or make a vacuum plate to hold them 2nd op in the mill. Why do such high quality work if you are only going to go 90% of the way. I realize this might be hard to understand I can try to explain better if needed.
@bcbloc02
@bcbloc02 6 жыл бұрын
Now with that fancy high end foam the cases look cheap. You need to engrave your logo on the outside of the cases now, decals just look cheap and after thought compared to the rest.
@Eggsr2bcrushed
@Eggsr2bcrushed 6 жыл бұрын
The decals look fine. It is a case for shipping, nothing more in my opinion. The knife belongs in your pocket, not a case.
@merrell_io
@merrell_io 6 жыл бұрын
Engraved on a rectangle of metal.
@josher89
@josher89 6 жыл бұрын
Eggsr2bcrushed I agree. Knife belongs in your pocket. If you are a collector, I doubt you'll use the plastic box for display purposes.
@Chris-yy7qc
@Chris-yy7qc 6 жыл бұрын
Agree, especially the first version of the top lid foam with the large engraving looked sooooo goood (1:20). And he replaced it with that ultra cheap looking knob foam. 3:20
@antanasrapkevicius3897
@antanasrapkevicius3897 5 жыл бұрын
beter make a freaking top quality knife instead of focusing on some cases and paddings.. as a customer i dont buy $50 knife, where the knife itself is a tenner and the case costs $40.. i buy 50 quid knife where the knife is $49 and the packaging is a quid!
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