Hi all,
I might have a bit of idea/information since I have done a bit of CNC (just like woodworking : just a hobby).
I have done a bit of foam milling in my CNC to organise my tools. By this time it was not in Festool systainer but it applies.
I must say though : I have not done a lot ... but I did a little bit and they came out pretty nicely.
Bit selection : except if you have a vaccum table it is not advised to use an upcut milling bit. It will pull on the foam and you won't have straight cuts. if you do have a vaccum table : lucky you
Bit rotation speed : this will apply as well to speed, but the idea is that foam is plastic. And just like plastic you should avoid as much as you can to create heat. the plastic would then melt, stick and you'll get a mess. So choose the slowest speed on your router. Try to cut some chucks of foam rather than make dust of it.
Moving speed : same idea, you do not want to generate any heat. So : go fast. The cool thing is that because it's foam and it's very easy to mill through it, you can go fast and kind of deep at the same time (which you wouldn't do with wood or metal).
Foam selection : I would advise for a higher density, closed cell. Here in Frace we have "plastazote", 45kg/m3 (if I remember well).
Here you can find a picture of some guy who milled some plastazote:
https://www.usinages.com/threads/cn-shapeoko.55338/
(I got some of my milling information from there)
Here is a small piece I had done :
View attachment 1
I had done some other pieces ... but can't find the pictures. If I find them, I'll post them.
My CNC is a shapeoko 2. the hardest part is to have the milling parameters. Then when you have a correct set that will give you a nice finish, the most annoying part is to do the drawings of your tools.
I found as well that is looked nice to have the exact drawings of tools. But the most useful space were some spare rectangular pockets I had done : you put there all the bits and pieces, the pens, adaptors, etc.
