High Density Foam Machining

At Data 2 Patterns, we specialise in the precision machining of high-density foams, with particular expertise in cutting Rohacell® — a rigid, closed-cell polymethacrylimide (PMI) foam widely used in the aerospace and autosport industries. Known for its exceptional stiffness-to-weight ratio, thermal stability, and resistance to compression, Rohacell is an ideal core material in composite structures where performance and weight savings are critical. Our team has extensive experience producing accurate, reliable foam components that meet the demanding standards of high-performance sectors. In addition to Rohacell, we also machine Airex® and high-density polyurethane foams, offering a complete service for customers requiring lightweight, durable, and dimensionally stable tooling and components.