CNC Milling from EPS, XPS, PUR Foam, and EPP — Large formats up to 6.3 m for Trade Shows, Stage, Industry, and Packaging
Kunststoffverarbeitung Schneppenheim GmbH
Pulheim (Schlehenweg 11) · GermanyNew on Amplifa
Family Company since 1970 — CNC Milling from Hard Foam
Kunststoffverarbeitung Schneppenheim GmbH is a family-owned company founded in 1970 in Pulheim near Cologne, which is now managed in the second generation by Carl-Heinz Schneppenheim. The company manufactures CNC-milled 3D objects from foams and hard foams: EPS (Styropor), XPS (Styrodur), PUR Foam, and EPP (Neopollen) in densities from 15 to 700 kg/m³. On large format CNC gantry milling machines with 3-axis and 5-axis processing, individual parts up to 6,300 x 3,000 x 1,500 mm are created; larger objects are connected seamlessly from segments. The value creation encompasses data preparation and CAD design, CNC manufacturing, puttying, painting in RAL, NCS, and Pantone, Polyurea and GFK coating, as well as packaging and delivery. Typical products include 3D letters and logos, trade show and stage scenery, prototypes, mold models for sand casting and lost foam, architectural models, as well as custom packaging and transport protection. Customers come from trade show construction, stage construction, advertising technology, foundry technology, automotive and mechanical engineering, as well as museums. Deliveries are provided in the DACH region; the award of the Ludwig-Erhard Prize attests to the company's quality.
- Site
- Pulheim
- Processes
- CNC Milling of Foams/Hard Foams (3-Axis), 5-Axis CNC Milling / 5-Axis Simultaneous Machining, Manufacturing of Foundry Models, Sand Casting, and Lost Foam Models, Polyurea Coating, GFK Laminating/Coating, Puttying and Painting (RAL, NCS, Pantone), 3D Scan and Data Preparation / CAD Design, Gluing/Joining of Segments into Large Objects (seamless)
- Materials
- EPS (Styropor), XPS (Styrodur), PUR Hard Foam, EPP (Neopolen), EPS (Styropor®), XPS (Styrodur®), 5-Axis CNC Milling, Polyurea Coating
- Certificates
- Ludwig-Erhard Prize (Award)
- Founded
- 1970
- Industries
- Trade Show Construction & Events, Stage & Scenery Construction, Decoration & Advertising Objects / Advertising Technology, Art Packaging / Museums, Prototypes & Model Making, Foundry Technology & Mold Making
- 01
Inquiry & Material Consultation
- 02
Data Preparation / CAD Design & 3D Scanning
- 03
CNC Milling (3-Axis / 5-Axis)
- 04
Joining & Gluing of Segments
- 05
Puttying, Coating (Polyurea/GFK) & Painting
- 06
Packaging & Delivery
Materials & Processes
EPS (Styropor®)
Light, economical foam (15–35 kg/m³) for trade show objects, scenery, architectural models, and lost foam casting, also available as flame-retardant B1 variant.
XPS (Styrodur®)
Extruded foam with a fine, closed-cell structure and high compressive strength, water-resistant and paintable for precision models and outdoor use.
PUR Hard Foam
High-density, pore-free hard foam (80–700 kg/m³) with the highest milling precision down to ±0.1 mm for prototypes, mold models, jigs, and tool models.
EPP (Neopolen)
Elastic thermoplastic with over 95% recovery and temperature resistance up to 130 °C, suitable for transport protection, crash absorbers, and reusable packaging.
5-Axis CNC Milling
Simultaneous machining of complex free-form surfaces in PUR, EPS, and XPS with tolerances up to ±0.1 mm without rework.
Polyurea Coating
Hard coating that makes milled foam objects scratch- and impact-resistant, allowing for permanent outdoor use.
GFK Laminating
Fiber-reinforced plastic coating for rock-hard surfaces, optically comparable to concrete, natural stone, or metal.
Painting & Puttying
Surface finishing in any RAL, NCS, and Pantone colors, including metallic, gold, and glitter finishes.
Full-Form Casting Models (Lost Foam)
CNC-milled EPS models that vaporize during sand casting, including shrinkage allowance and machining allowance.
Locations
Pulheim
DEProduction & Administration
- Part weight / size
- Individual pieces up to 6.3 m in length, typically ~30–120
- Lot size
- Individual piece to small series
- Materials
- EPS, XPS, PUR Hard Foam, EPP
- Large format CNC gantry milling machine (6,300 x 3,000 x 1,500 mm)
- 5-Axis CNC machine
- 3D Scanner
- Coating and Painting System
Components & Objects
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| CNC Milling of Foams/Hard Foams (3-Axis)Machining | ±0,5 mm | 6.300 mm × 3.000 mm × 1.500 mm | – | Individual piece – Small series | EPS, XPS, PUR Hard Foam, EPP |
| 5-Axis CNC Milling / 5-Axis Simultaneous MachiningMachining | ±0,1 mm | 6.300 mm × 3.000 mm × 1.500 mm | – | Individual piece – Small series | PUR Hard Foam, EPS, XPS |
| Manufacturing of Foundry Models, Sand Casting, and Lost Foam ModelsCasting | ±0,2 mm (Foundry models with shrinkage allowance) | 6.300 mm | – | – | PUR Hard Foam, EPS |
| Polyurea CoatingSurface | – | – | – | – | EPS, XPS, PUR Hard Foam, EPP |
| GFK Laminating/CoatingSurface | – | – | – | – | EPS, XPS |
| Puttying and Painting (RAL, NCS, Pantone)Surface | – | – | – | – | EPS, XPS, PUR Hard Foam |
| 3D Scan and Data Preparation / CAD DesignEngineering | – | – | – | – | – |
| Gluing/Joining of Segments into Large Objects (seamless)Joining | – | – | – | – | EPS, XPS, PUR Hard Foam, EPP |
2 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Large format CNC gantry milling machine | – | – | 6.300 x 3.000 x 1.500 mm (L x B x H) | – | Pulheim |
| 5-Axis CNC machine | – | – | – | – | Pulheim |
Additional services
Reference customers
Quality & Awards
The manufacturing is performed with documented tolerances of ±0.5 mm on 3-axis and ±0.1 mm on 5-axis machines; for foundry models, shrinkage dimensions are already taken into account in the CAD design. The company has been awarded the Ludwig-Erhard Prize.
| Evidence | Pulheim |
|---|---|
| Ludwig-Erhard Prize (Award) |
Company History
- 1970
Founding of the family business by the first generation of the owning family
Takeover of management by Carl-Heinz Schneppenheim in the second generation; over 50 years of company history and award with the Ludwig-Erhard Prize