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Routing Ultraboard foam speeds and feeds smooth edge

Discussion in 'Dimensional Signs' started by nolanola, Jul 11, 2018.

  1. nolanola

    nolanola Member

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    Sep 24, 2014
    New Orleans
    Hello.
    I was in a grocery store and noticed that nice sign with a smooth edge (yellow, image attached).
    I assume it's ultraboard.
    We can not achieve that.
    What bit and what speeds and feeds do you use?

    Ultraboard website says:
    Onsrud bit # 52-564 (2 flute, upcut, 1/4", 2-1/4", 1/4" feed rate 125” per minute run at 18,000 rpm)

    We used a similar bit, and even after heavy priming and sanding the edges would be ugly (green, image attached).

    Thank you.
     

    Attached Files:

    Tags:
  2. Superior_Adam

    Superior_Adam Member

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    Dec 13, 2017
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    That yellow sign does not look like UltraBoard Foam Substrate. It looks more like a PVC to me. On foam products we knife cut them on our Zund.
     
  3. AGCharlotte

    AGCharlotte Member

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    Feb 28, 2018
    Charlotte, NC
    agree w/ Adam... that's not ultraboard, it's some sort of solid plastic.
     
  4. Sandman

    Sandman Member

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    Crystal Falls, MI
    The yellow one looks exactly like expanded PVC like Celtec or Komatex.
     
  5. Grizzly

    Grizzly Member

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    I don't print a lot of Ultraboard but I do I print a lot of Gatorfoam. It is very prone to bit direction. Going one direction looks good while the other doesn't. Maybe you've already tried that and maybe Ultraboard foam doesn't react the same way but it's worth a shot.
     
    • Agree Agree x 1
  6. JBurton

    JBurton Custom Applications Specialist

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    I have had several types of foam that required different directionality on the cuts. One was an ultraboard with metal laminate, that one required cutting the laminate with a standard bit and then cutting the foam in the opposite direction with a double fluted bit. It is also very prone to melting/bunching up when cut with too slowly, or with too high of a rotation. The directional issue is one to identify because the drops look better than the letters.
     
  7. nolanola

    nolanola Member

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    Sep 24, 2014
    New Orleans
    Is it different from regular PVC (like Sintra or Ion).
    Where do you order it from?

    Thank you.
     
  8. Andy D

    Andy D Premium Subscriber

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    Oct 20, 2014
    Hattiesburg, MS
    I worked at a place a few years back that cut a lot of coro, foam board, gator board, sintra, even cardboard &
    their router had a completely different head for every substrate... for example, the foam board was a vibrating straight edge blade.
     
  9. Pitzu

    Pitzu Member

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    May 2, 2018
    Romania
    Looks like high density extruded polystyrene...we cut it every day for letters. We usually use Datron - Triple flute end mill with toric cut for PU foam, using conventional milling.... and the finish is like the yellow letters. Even so, we don't consider it smooth edge. Hot wire cut is a lot smoother.
    In foam board the core doesn't have high density as the extruded polystyrene and the edge ends up like the green letter. Oscillating knife might give a better finish.
     
  10. nolanola

    nolanola Member

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    New Orleans
    Great.
    Who supplies high density extruded polystyrene?
    What brands do you use?
     
  11. Emd2kick

    Emd2kick Member

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    Jan 18, 2018
    New Jersey
    Andy, it's called an oscillating knife.
     
  12. Pitzu

    Pitzu Member

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    Romania
    I don't know if the brand we use (Apla XPS RF) is found in the US, but the most important is to be high density and have smooth faces, since you can also find models with rugged faces. It's widely used in construction for thermal insulation. We mostly use water based paint, since the solvent based paint will melt the foam.
    High density polyurethane sheets should work also. I believe these could give you a better finish than extruded polystirene. You have to do some tests. These are also used in construction for thermal insulation.
    For special applications there is Necuron: http://necumer.com/index.php/en/products/board-materials
    In the US there is Corafoam https://www.dunagroup.com/usa/products/foams/corafoam-high-density
     
    Last edited: Jul 13, 2018
    • Informative Informative x 1
  13. The Sign Depot LLC

    The Sign Depot LLC New Member

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    Oct 14, 2017
    OK
    As others have mentioned, the Claude sign looks more like expanded foam PVC with machines pretty well and it's much denser than Ultraboard so it will accept paint better. However, you can do it with Ultraboard if you're looking for something cheaper then PVC. For feeds and speeds, we use Belin 13317A which is a 1/8" single flute upcut spiral for plastic at 50ipm at 22,000 rpm. Its works beautifully.

    Sent from my SM-N950U using Tapatalk
     
    • Informative Informative x 1
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