Bending and forming foam board

[David Rogers]

Yup.

Used several in the past – some commercial, some home made.

hot line bender is the best way for a crisp, tight line.

Flat table with a heated wire running in a gap – adjustable temp…great for heat-bending most sheet materials.

http://www.shannon.nl/index_ENG/sub/kun … hines.htm#

Home-made versions available!

http://www.mp3car.com/vbulletin/fabrica … -less.html

Dave

[Stephen Ingham]

Hi David, thanks for the reply.

Its probably a little more involved than i had expected….

cheers
stephen

[Graham . Shand]

quote Stephen Ingham:

Hi all, can anyone recommend a method of bending and forming a piece of say 3 or 5mm foam board?

I have a piece of board measuring approx 1000mm square that i need to put a 90 degree bend in, has anyone ever done this, putting a bend in and it staying there?

Any help and advice is much appreciated.

cheers
stephen

http://hotwirefoamfactory.com/home.php they do have suppliers in the uk
and are also on sale on a well known auction site

[David Rogers]

I can only see styrofoam sculpting kit, not PVC / acrylic bending kit on the website.

[Graham . Shand]

quote David Rogers:

I can only see styrofoam sculpting kit, not PVC / acrylic bending kit on the website.

I use the adjustable heat controller.

[David Rogers]

quote Graham.Shand:

quote David Rogers:

I can only see styrofoam sculpting kit, not PVC / acrylic bending kit on the website.

I use the adjustable heat controller.

Ah. Gotcha

What’s your setup? A tensioned nickel wire strung over a bench?

Dave

[Graham . Shand]

quote David Rogers:

quote Graham.Shand:

quote David Rogers:

I can only see styrofoam sculpting kit, not PVC / acrylic bending kit on the website.

I use the adjustable heat controller.

Ah. Gotcha

What’s your setup? A tensioned nickel wire strung over a bench?

Dave

dempends how large the piece is, but I have used a very long wire, but getting a straight line can be tricky, using springs on each end can fix this issue, a self tensioned bow can also be used, various sizes (similar to the "big bow" can be made from pvc pipe, now bending that is a whole new world LOL

[David Rowland]

we have heat bender, 3mm bends well.

Another way is the router a 2-3mm groove using a 3mm bit into 5mm FX, then use hot-air guns and a long table, put join on table and heat until it bends, using gravity and table edge you would get a reasonable 90deg bend, wont be perfect but it will be bent. Groove facing upwards btw.

[Graham . Shand]

quote Dave Rowland:

we have heat bender, 3mm bends well.

Another way is the router a 2-3mm groove using a 3mm bit into 5mm FX, then use hot-air guns and a long table, put join on table and heat until it bends, using gravity and table edge you would get a reasonable 90deg bend, wont be perfect but it will be bent. Groove facing upwards btw.

Dave , perhaps you can help me out here, I have been looking for V shaped router bits for Aluminum, can you recommend a supplier / link, cheers Graham S

[Stephen Ingham]

Thanks for all of your help and advice.

It is probably only going to be a one off so a simple method is preferred. Would it be possible to route it like you would with composite board when making a sign tray with a 90 degree router bit and then bend it and bond it?

Hope that makes sense?

cheers
stephen

[David Rowland]

Graham, I bought mine from Axminster but they dont sell them anymore

This will cut dibond, it is trend if i recall correctly and has the 1mm flat.
http://www.powertooldirect.co.uk/trend_ … 79883.html

Stephen, did u read my reply? I would suggest 3mm flat router bit, just a normal one not a V as u bend the other way.

[David Rogers]

Now, here’s a little trick for using foam PVC if bending is just going to be a lot of hassle.

Personally I’d not be tempted to route & bend with a heat gun as the heat distribution is to random and a clean bend is near impossible unless you drape it over a bench…and pray.

Bog standard cyanoacrylate superglue 🙂

The bond generated with standard superglue on PVC foam board is amazing – MUCH stronger than the actual material.

Try it on some scraps.

you will need very clean & square edges (sawn not knife cut) – NO defects – as the mating surfaces need to be in contact.

Masking tape hinge so you align the edge perfectly – run in a bead of glue, set to 90 degrees…done.

There are even better glues – but they melt the PVC and it gets messy.

[Graham . Shand]

quote Dave Rowland:

Graham, I bought mine from Axminster but they dont sell them anymore

This will cut dibond, it is trend if i recall correctly and has the 1mm flat.
http://www.powertooldirect.co.uk/trend_ … 79883.html

Stephen, did u read my reply? I would suggest 3mm flat router bit, just a normal one not a V as u bend the other way.

Cheers Dave, much appreciated

[Stephen Ingham]

Thanks again for the replies.

Sorry dave, i think i miss read your reply, a flat bit not a "V".

David when you say "Bog standard cyanoacrylate superglue" any clues as to where to buy it from?

That may sound like a draft question, if it is i apologise.

cheers
stephen

[David Rogers]

quote Stephen Ingham:

Thanks again for the replies.

Sorry dave, i think i miss read your reply, a flat bit not a “V”.

David when you say “Bog standard cyanoacrylate superglue” any clues as to where to buy it from?

That may sound like a draft question, if it is i apologise.

cheers
stephen

It’s just ‘superglue’ – B&Q should sell a nice big bottle of the stuff (20ml or so).

[Stephen Ingham]

Cheers David i’ll give that a try.

stephen