Complete technical specifications for CNC machining EVA foam in medical orthotic applications. Expert parameters, tooling selection, and quality control techniques for orthotic CNC milling machines.
| EVA Density (Shore A) | Spindle Speed (RPM) | Feed Rate (IPM) | Depth of Cut (mm) | Surface Finish |
|---|---|---|---|---|
| 15-25 (Soft) | 6,000-8,000 | 60-80 | 0.3-0.5 | Ra 2.0-3.0μm |
| 25-35 (Medium-Soft) | 8,000-10,000 | 50-70 | 0.4-0.6 | Ra 1.8-2.5μm |
| 35-45 (Medium) | 10,000-12,000 | 40-60 | 0.5-0.8 | Ra 1.6-2.0μm |
| 45-55 (Medium-Firm) | 12,000-15,000 | 35-50 | 0.6-1.0 | Ra 1.4-1.8μm |
| 55-70 (Firm) | 15,000-18,000 | 30-45 | 0.8-1.2 | Ra 1.2-1.6μm |
Sharp cutting edges with positive rake angle for clean cuts. These work optimally with professional orthotic CNC milling machines designed for medical applications.
For 3D contouring and complex geometry finishing
Purpose-built tools for foam machining
TiN, TiAlN coatings cause material buildup
Too many flutes restrict chip flow
Poor edge condition causes defects
Measure critical dimensions within ±0.1mm tolerance
Verify Ra values and absence of tool marks
Check for burrs, tears, or rough edges
Inspect for heat damage or material changes
Cause: Too slow feed rate, dull tools
Solution: Increase feed rate, replace tools
Cause: Wrong tool geometry, vibration
Solution: Use sharper tools, improve fixturing
Cause: Tool deflection, thermal expansion
Solution: Shorter tools, temperature control
Cause: Inadequate chip evacuation
Solution: Air blast, vacuum system
Our CNC systems are specifically engineered for EVA foam orthotic production with optimized parameters and proven results.
Systems ship with optimized EVA foam machining parameters
Comprehensive training on EVA foam best practices
24/7 access to EVA foam machining specialists
Shore A 25-55 densities machine most consistently. Softer foams (15-25) require more careful parameter control, while firmer foams (55-70) can handle more aggressive cuts but may produce more heat.
Use vacuum workholding systems that distribute clamping force evenly. Avoid mechanical clamps that can compress the foam. Set vacuum pressure to 15-20 inches Hg for optimal holding without distortion.
Carbide end mills typically last 50-100 hours of machining time on EVA foam. Tool life depends on material density, cutting parameters, and tool quality. Replace tools when surface finish degrades.
Yes, but adjust parameters for each density. Start with the firmest material using higher speeds, then reduce parameters for softer materials. This prevents tool loading and maintains quality across all parts.