Milling foam rubber - which tools ?

Hello,

i am trying to find the right end mill for cutting soft foam sheets. I'm not sure what the exact material is, in Germany different variants of this material go under the name of "Schaumstoff", Wikipedia says it's called 'Foam Rubber' in English, Google translates it as 'Foam material'.

I have tried out different types of end mills and so far the best result is with a 5 flute new and ultrasharp bit ... 1, 2 flute and 3 flute don't work so well but at the moment i don't have any new super sharp ones.

heres one of the tests i did, it's usable but i'm really looking for a much better finish.

Attachment 247176

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The guys i usually buy my tools from have a new type of mill specially for this material:

Schaumstofffräser von DATRON - YouTube

but they're quite expensive and the type of foam they're cutting in this video is much denser than the one i want to use.

Does anyone have any experience with this type of material ?

looks like polyethylene foam and best water jetting it or hotwire cutting . also the density on what datron is using is higher than what you're working with .

tony

that looks like foam rubber. Hot wire it, don't mill it.