Foam_Shapes

We've done a lot of shapes in the high-end residential industry and for small businesses - so, yes. However, pricing is probably prohibitive to the average consumer.

The size of most of our shapes are so big that 3D printing would not be practical where the technology currently stands. We've upgraded our machines many times over the years as technology has advanced and we plan on doing so as new and better ways of doing things emerge.

Someone asked about stress working with the movie industry and what other movies and shows we've done, and then deleted their question, hope this answers it : Always, the show must go on and production deadlines must be met. We made cannons for Gods and Generals, columns for the Manchurian Candidate, stone features for the castle in Black Knight, vents for MIB III, and an old cemetery in the woods for O Brother, Where Art Thou. We also did the architectural trim for the series Revolution, sand castle sculptures for The Glades, and a tombstone for Matlock. Just to name a few of probably thousands.

The high buoyancy of foam makes me want to make a houseboat out of it powered by solar panels...everyone I tell that to looks at me as if I'm crazy.

We have made quite a few props for TV shows and movies, one of the most noticeable being the giant bull from Year One. Pictures

I'm not permitted to name brands or exact limitations - however, I can reveal that we use 1 lb, 1.5 lb, and 2 lb EPS respectively. Hot-wire cutting velocity depends on the density of the foam, the detail of the shape, and the temperature of the wire. Our machines are big enough to cut multiple 10 foot blocks simultaneously in one piece.