3D Foam Carving & CNC Prototyping
At Woven CNC, we offer 3D foam carving and CNC machining for prototypes, moulds, patterns, sculptural forms and bespoke design projects. Using digital 3D modelling and CNC routing, we can turn sketches, CAD files or rough ideas into accurate physical forms ready for testing, mould-making, coating or further development.
This service is ideal for car part prototyping, concrete moulds, architectural features, signage, product development, display work, sculpture and one-off creative projects.
This service is particularly useful where a project needs a large physical form without the cost, weight or machining time of solid timber, resin tooling board or metal.
Fusion 360 3D Modelling & CAD Preparation
We can also provide 3D modelling and CAD preparation using Fusion 360. This is useful when a project starts as a sketch, reference image, physical sample or rough concept rather than a finished CAD file.
Depending on the project, we can create or refine 3D models, prepare machining strategies, split large forms into sections, add fixing points, create repeatable components and prepare files ready for CNC machining.
Common Uses for 3D Foam Machining
Foam is a practical material for producing large, lightweight and cost-effective shapes before committing to more expensive manufacturing methods. It can be used for visual prototypes, plug forms, mould patterns, casting masters, display pieces and design development.
Whether you need a one-off prototype, a carved foam master for a concrete mould, or a complex 3D shape machined from a digital model, we can help take the project from concept through to CNC-cut form.
The process usually starts with your drawing, sketch, CAD file, reference image or dimensions. From there we can assess the best way to produce the part, including material choice, model preparation, machining time, section sizes and finishing requirements.
For larger or more complex projects, we can split the model into manageable sections for machining and assembly.
Send us your sketch, drawing, CAD file or reference images
We review the shape, scale, material and intended use
3D modelling or file preparation if required
CNC toolpaths are created
Foam is machined on our CNC router
Parts are supplied ready for coating, mould-making, assembly or further finishing
From Idea to Machined Foam Part
3D CNC Foam Carving for Prototypes, Moulds & Bespoke Projects
Car Part Prototyping
Foam bucks, styling models, bodywork mock-ups, plug forms and custom vehicle part development.
Concrete Moulds & Casting Patterns
Foam masters, mould patterns, shaped formwork and one-off forms for concrete furniture, sinks, panels and architectural pieces.
Product Design & Development
Physical prototypes, test shapes, ergonomic forms and concept models for early-stage product development.
Signage, Display & Props
Large letters, sculptural features, exhibition pieces, retail displays, event props and branded installations.
Architectural & Interior Features
Curved panels, relief forms, decorative features, wall panels and bespoke components.
We can machine suitable foam materials depending on the project requirements, scale and finish needed. Foam machining is generally used for prototypes, patterns, masters and forms rather than finished structural parts.
Depending on the project, this may include machining suitable foam materials such as xps foam, insulation foam, modelling foam or other machinable foam boards.
The final surface quality depends on the foam type, cutter size, model detail, machining strategy and any post-processing required. Some projects may need sanding, coating, sealing or further finishing after CNC machining.
We can offer a coating service to help harden and protect the foam. Further filling, sanding and finishing may still be required if a smooth painted or production-ready surface is needed. We do not currently offer full finishing, filling or painting as part of this service.
Materials & Finish
Based in Middlesbrough - Working nationally, Across Teesside, Newcastle & the North East
Woven CNC is based in Middlesbrough, next to Cleveland Timber, and works with clients across Teesside, Newcastle, County Durham, North Yorkshire and the wider North East and UK. We offer CNC routing, 3D foam carving, CAD preparation and bespoke machining for trade, commercial and creative projects.
Send over your sketch, CAD file, reference images, dimensions and a short explanation of what the part will be used for. We can advise whether the project is best suited to foam carving, MDF machining, mould-making or another CNC process.
If you are unsure exactly how the part should be made, we can advise on the best route before machining.