Evil Mad Scientist‘s blog has an interesting post on how egg crate foam is manufactured. Cool video!
Ever wonder how they make foam rubber into an “egg crate” shape? You can tell that it isn’t molded that way, because there is not a smooth skin on the surfaces. And it clearly isn’t milled to that shape, since it comes in matched top and bottom pieces that are cut from the same initial block of foam. So how is it done? Amazingly enough, it’s done with a bandsaw.
Egg crate, acoustic, and other shapes of “convoluted foam” are cut with a special machine called a convolutor, which uses powerful rollers to feed flat sheets of foam rubber into a high-tension bandsaw. The rollers are covered with bumps that stretch and distort the foam such that the saw cuts to a variable depth, with extremely little waste.
You can watch the process in this video from Italian Cutting Systems (noting that the bandsaws are hidden behind protective covers).
Adafruit publishes a wide range of writing and video content, including interviews and reporting on the maker market and the wider technology world. Our standards page is intended as a guide to best practices that Adafruit uses, as well as an outline of the ethical standards Adafruit aspires to. While Adafruit is not an independent journalistic institution, Adafruit strives to be a fair, informative, and positive voice within the community – check it out here: adafruit.com/editorialstandards
Stop breadboarding and soldering – start making immediately! Adafruit’s Circuit Playground is jam-packed with LEDs, sensors, buttons, alligator clip pads and more. Build projects with Circuit Playground in a few minutes with the drag-and-drop MakeCode programming site, learn computer science using the CS Discoveries class on code.org, jump into CircuitPython to learn Python and hardware together, TinyGO, or even use the Arduino IDE. Circuit Playground Express is the newest and best Circuit Playground board, with support for CircuitPython, MakeCode, and Arduino. It has a powerful processor, 10 NeoPixels, mini speaker, InfraRed receive and transmit, two buttons, a switch, 14 alligator clip pads, and lots of sensors: capacitive touch, IR proximity, temperature, light, motion and sound. A whole wide world of electronics and coding is waiting for you, and it fits in the palm of your hand.
Have an amazing project to share? The Electronics Show and Tell is every Wednesday at 7pm ET! To join, head over to YouTube and check out the show’s live chat – we’ll post the link there.