FROGBlog - 3D Foam Carving Central

The hard coating process is a critical step in the automated foam carving production process. As our most recent article explains, cutting corners at this stage can be disastrous. This means that you have to do your research when choosing the right coating material for the job - here are some of the most important considerations.

CHOOSING THE RIGHT HARD COATING MATERIAL FOR FOAM CARVING AND CUTTING PROJECTS

For many 3D foam cutting and carving applications, hard coating the foam is an integral step in the production process. Coatings not only provide the final product with strength and durability, but they’re also very important for the quality of its final appearance. Application methods are important, but don’t jump the gun. Before you go anywhere near your spraying equipment, it’s absolutely critical that you choose the right coating material for the job. We’re not just talking about finding the cheapest product, because that is often a recipe for disaster. Your choice could be the difference between a product that lasts and one that is quickly compromised by its environment. With many different coating products on the market, it can be a challenge to determine the ideal coating for the job. While there may be unique circumstances depending on the project, the following outlines some of the key factors that should be considered.

1. Environment
The nature of the environment your project will be exposed to is perhaps the most important factor in determining the choice of a coating material. If the project will live in a climate-controlled interior environment, you’ll be able to choose from a much wider range of coating products - most will hold up well in stable, moderate environments. It’s when things are taken outdoors that the potential problems can mount. Moisture, humidity, heat and cold will have different effects on different coatings and each can affect the integrity of your coated project. Throw in extreme weather or constant temperature fluctuations and the potential for damage is multiplied. With the wrong coatings, cracking, flaking and bubbling can result. By considering the main environmental elements at play and choosing a properly formulated coating, you’ll be able to avoid these kinds of failures. For exterior and extreme environments, pure polyurea coatings are often the best choice. Polyurea is UV resistant and also dimensionally stable in both very high and very low temperatures, so it will hold up well in most exterior environments.

2. Traffic and Handling
Whether inside or outside, the right coating material for your job will depend on how much traffic and handling your project is going to undergo. Is this a piece that will be completely out of reach? Will people be touching it? Will kids be climbing it? Is it a potential target of vandalism? If the piece will be subjected to a lot of this kind of traffic, you’ll have to choose a coating material that can handle the abuse. For very high traffic, a pure polyurea coating tends to offer the best protection, with hybrid and polyurethane products being good choices for lower traffic environments.

3. Texture
Your choice of coating will also depend on the kind of texture the final piece needs to have. If it’s smoothness you need, there are coatings that have longer cure times, which allows the material to settle for a longer period of time and create a smoother surface. There are also certain coatings that will cure harder and therefore offer better workability with air tools and conventional sanding processes. If your end product requires a textured surface, products with faster curing times are often useful for applying stippled coats. In considering the texture of the piece, you should also take standard viewing distances into account. For pieces that will only be viewed from afar, a slightly textured surface is often acceptable as viewers will not be able to see the details. It will also reduce the amount of surface sanding required compared to products that require a very smooth finish. If your end product requires a specific look, be it concrete, bark or skin, there are coatings that, when applied correctly, can create a more realistic look and feel.

4. Fire Rating
If your product needs to be fire-rated, this will impact your choice of coatings. You’ll find various coating products that come in both fire-rated and non-fire-rated versions. Note that the fire-rated versions will often be less dimensionally stable than their non-fire-rated cousins.

While this is not a comprehensive list, these considerations are a good starting point for narrowing down your coating choices for foam carving and cutting projects. It is important to note that there are trade-offs across the various products. Fire-rated coatings might be less dimensionally stable. Hard coatings that are easily sanded may not be recommended for extreme weather or durability requirements. Stronger polyurea coatings tend to be more costly. You’ll have to find the right mix of qualities to match your particular requirements. The bottom line, however, is that the coating stage is not the time to cut corners. Projects that have taken countless hours to get to the coating stage can be swiftly destroyed with the wrong kind of coating. Make sure you get it right the first time – because second chances will be costly.

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