Patent ID: 6941188
Filing Date: 2005-09-06
Classification: B23C,B29C,Y10T

Abstract:
1. A method of making a contoured foam body from a block of foam, comprising: programming a milling machine with coordinates for a desired surface contour of a first side and a second side of the contoured foam body; cutting the block of foam using the milling machine to remove a portion of a first side of the foam block to the depth of the desired surface contour to form at least one pocket while leaving at least one supporting portion of the foam block intact on the first side of the foam body, wherein the supporting portion is a grid that extends in a direction normal to an outer surface of the block of foam to the surface contour of the contoured foam body; cutting the block of foam using the milling machine to remove the second side of the foam block to the depth of the desired surface contour, the second side being on the opposite side of the foam block from the first side; cutting the first side of the foam block to remove the supporting portion proximate the desired surface contour, wherein by removing the supporting portion the first side of the foam body is formed to the desired surface contour.