As you may remember, Lightning Hybrids has a DMS CNC 5-axis router. This machine is capable of cutting foam or MDF. It is equipped with two 5x5 foot tables allowing us to place and cut parts that are about 4.5 feet by 9 feet.
Our machine has 4 feet of vertical Z movement allowing us to effectively cut a 3.5 foot tall part in one single operation (fixture). With this machine, we can prototype complicated geometries that a traditional 3-axis machine is incapable of. Our costs also run lower, since we can utilize flat cutters to create complex curves.
As you know, we used this router to produce our aerodynamic 3D vehicle shapes. Our entire car body was created - from foam blocks to a finished product - in less than three weeks.
We use MasterCAM X3 for our 5-axis programming, and can convert 3D drawings to toolpaths using MasterCAM in less than two days.
If you need something produced, we'd be happy to work with you to create the part you have been designing. For more information please email Chris at lightninghybrids dot com with a description or part file for high or low production numbers.