Recently, PrecisionRobo Tech, a leading provider of industrial robotic solutions, has successfully delivered and commissioned custom-built milling robot arm systems for multiple factory clients, specifically tailored to their core demand: high-precision foam model carving. The deployment addresses the unique challenges of foam processing—such as material fragility and low tolerance for deformation—marking a significant upgrade from traditional manual or semi-automated foam carving methods.

The customers, spanning industries including film prop manufacturing, architectural model design, and toy prototype development, had long faced pain points with conventional foam carving: manual work yielded low efficiency (only 1-2 models per worker daily), frequent material waste due to easy foam chipping, and difficulty achieving consistent precision (errors often exceeding 1mm). Their key requirement was a robotic solution that could handle foam’s soft, porous properties while meeting strict model detail and production speed targets.

To meet these needs, PrecisionRobo Tech’s engineering team customized the milling robot arms with three critical features for foam processing:

During on-site implementation, the PrecisionRobo Tech team completed installation, calibration, and operator training within one week. Initial test runs showed remarkable results: the milling robot arms increased foam model production efficiency by 5x (now 8-10 models per robot daily), reduced material waste by 80%, and controlled carving precision within ±0.3mm—fully meeting the customers’ quality standards.

“We specialize in creating large-scale foam scenery models for film and television productions, where both speed and detail are non-negotiable,” said a production manager from one of the client factories. “The milling robot arms from PrecisionRobo Tech not only cut our delivery time for foam models in half but also perfectly replicate the intricate textures we need—something manual carving could never consistently achieve.”

This project highlights PrecisionRobo Tech’s ability to adapt milling robot arm technology to niche material processing needs. Traditionally used for metal or plastic machining, the customized systems now open new applications in foam-based manufacturing. Looking ahead, the company plans to further optimize the robot arms for different foam densities (from EVA foam to rigid polyurethane foam) and expand services to clients in the entertainment and educational model-making sectors.