Impressive listing!
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Laser cutting foam is a workable thing. Definitely want it happening in an enclosure because of fumes. It can do a “melt / contract” thing when you cut it, which can have the top of the foam shrunk away from the bottom, and overall size not quite what was drawn. By a little experimentation you can account for this in the design.
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Thanks Doug!
Well I know at least one person found the new product listing (Not the LR4) because I already got one order for it last night. Hopefully the way I have it linked from the LR4 listing it was easy to find.
Found this the other day. Going to buy it for my cnc bed. I want to do halloween, christmas lanterns without destroying my mdf.
https://www.homedepot.com/p/R-Tech-1-in-x-48-in-x-8-ft-R-3-85-Insulating-Sheathing-320821/202532854
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I tried something like that for a spoil board when I first built my LR3 and it didn’t work well. When you screw down your work piece the foam compresses.
As long as your spoilboard is flat and you do your cam correctly you don’t tear the spoil board up bad at all
Looks great!
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Thinkng i will use masking tape ca glue method!
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You may want to try using low expansion foam at first. The big gap great stuff is a lot harder to estimate how much to use… and how much it is going to expand.
…although depending on how thick you need the foam to be, you may need the big gap high expansion version.
In any case, I would form the foam pieces over a mold (or duplicate components) rather than the product you are shipping. There’s an art to getting it just right that takes some practice. Too much foam expanding around a product in a confined space will break stuff.
That said, I really like the idea of cutting up 1" thick 4’ x 8’ sheets of foam (as noted by others, cheap at Home Depot) and gluing them together. Taking a boolean difference of what you want to surround with foam out of a cube and then slicing it into one inch pieces will give you what you need for patterns. You just have to, also, cut the outline of each successive slice out of the next slice (starting at the inner most slice of the foam piece) to ensure that you can pull off (or put on) foam end pieces. For pieces that go mid-span you’ll have to “C cut” them or cut them into matting pairs so that you can pull them off/put them on, probably with additional clearance cuts.
With respect to shipping, I know you guys have it a lot better with shipping rates down there, but netparcel.com may be worth looking at. Best rates from all the common carriers that I’ve seen here in Canadaland.
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I have seen expanding foam blow the drywall off the wall in a bathroom after the BIL Tried something new 
I recieved a outboard motor packed with spary foam and bags and was very nice. Spraied into the corners and crumpled paper to fill voids some not many in a outboard 7.5 HP so mot big
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Just finished assembling yours! Tomorrow I will get it all wired up and ready to go!
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I tried that once, don’t. 
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