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CNC Contour Cutting

Sondor can create customised shaped products through CNC contour cutting. All cross-linked or non-cross-linked foams of various densities for cushion, shock absorption, protective packaging, and flotation applications are suitable for CNC contour cutting.

How does CNC Contour Cutting work?

CNC foam contour cutting machines use a hot wire to melt through foam boards. The foam is placed on a cutting table, and the cutter moves along the surface of the foam board, melting the foam as it goes. The cutter can create any desired shape or design, making it ideal for many uses.


  • Contoured Foam is used as space fillers to ensure products are snugly packaged, preventing damage during transportation and storage
  • Load spreaders to protect against impact at certain points, spreading the shock over a large area
  • Cushion packaging protects against shock and vibration.
  • Used in agricultural processing applications for protecting fragile items such as fruit I.e. Fruit Rollers
  • Shaped Foam is ideal for applications requiring low surface abrasion and packaging of fragile products such as military equipment
  • Various flotation devices for marine and water applications (Polypython pool noodles, buoys etc)
  • Profiled foam for Sound Insulation such as Whisper. Profiling of sound insulation foam, such as Hush, increases the surface area and by so doing sound absorption improves over un-profiled Quash specifications


  • Sondor has highly versatile fabrication processes for solving many applications.
  • Sondor's CNC Machine produces a high-quality finish and edging, which adds value to the presentation of products.
  • The wide range of foams has excellent shock absorption, vibration damping, insulation, and buoyancy characteristics, as well as aesthetically appealing qualities.
  • Sondor quality foam products are resilient, compressible, and lightweight
  • Specialists available to assist with design, layout, and choice of materials
  • Any custom profile can be shaped out of a variety of our foam. And any profile up to 1m x 1m in 2m lengths.


With branches in Cape Town, Durban, Gauteng, Pretoria and Gqeberha, our knowledgeable representatives can advise the right solution for you. Find a branch near you for expert assistance. 

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