Foamlinx LLC and WeCutFoam have collaborated with Elytron Aircraft LLC to fabricate Elytron’s newly designed two-seater VTOL (Vertical takeoff and landing) aircraft. The unique modern aircraft prototype was created by cutting and machining foam using CNC hot wire foam cutters as well as CNC routers. The foam cores Foamlinx created were covered by Elytron using carbon fiber prepmeg to produce an innovative aircraft prototype that is an airplane capable of taking off and landing as a helicopter. Foamlinx started working on Elytron’s aircraft design in mid 2014. The fabrication company was given 3D CAD files which were analyzed locally and then fed to their CNC machines. To create some of the parts they used CNC hot wire foam cutters, while other parts were machined using CNC routers. Some parts were machined on a router as large as 16ft x 8ft x 4ft in size so that the parts could be made in one piece instead of in sections.
