Portfolio / CNC Prototype Patterns in Foam

Steven Holl Architects asked us to fabricate a series of sample panels in high-density polyurethane foam. The undulating panels were going to be used as patterns for a mock-up in concrete. Polyurethane foam is a good choice for such prototypes and samples as it can be machined far more quickly than wood or plastic. It is also far more forgiving on machines and tooling than wood or plastic if something goes wrong. While it is relatively expensive compared to cheaper foams like polystyrene, it is more durable and uniform across a wide array of thicknesses and densities.