Custom EVA Material For Orthotic Milling

Custom EVA Material for Orthotic Milling — Product Data

Product overview

Closed-cell EVA milling blocks/sheets engineered for CAD/CAM fabrication of custom orthoses, footbeds, and accommodative inserts. Tunable density and hardness deliver the right mix of cushioning, support, and long-term resilience for retail, hospitality, clinical, and athletic use.

Technical specifications

• Material: EVA closed-cell foam (latex-free)

• Applications: Orthotic milling, footbeds, heel lifts/posts, wedges, accommodative pads

• Density: Customizable (typical 0.12–0.28 g/cm³)

• Hardness: 25–80° Shore C (soft comfort → firm control)

• Thickness: 1–57 mm standard; thicker laminates on request

• Formats: Milling blocks / sheets / billets; laminated multi-durometer stacks available

• Colors: Any solid color or Pantone-matched; optional color-by-durometer system

• Origin: CN

• Feature: EVA orthopedic/orthotic sheet for CNC milling

Key benefits

• Consistent machining: Fine, closed cell structure mills cleanly with crisp edges and smooth surfaces.

• Comfort + control: Wide durometer range supports soft top layers with firm posting/stabilization under rearfoot/forefoot.

• Lightweight & resilient: Low compression set and reliable rebound for all-day wear.

• Hygienic & water-resistant: Closed cells resist moisture uptake; easy to clean and finish.

• Process-ready: Bonds well to common top-covers (mesh, PU, microfiber, cork) and to EVA/rubber posting materials.

Recommended hardness by use

• Top-cover / accommodative layers: 25–40° Shore C

• General orthotic shells / footbeds: 35–55° Shore C

• Posting, wedges, motion-control zones: 50–70° Shore C

• High-load work/industrial inserts: 60–80° Shore C

Options & customization

• Single, dual, or multi-durometer laminates (e.g., soft 30C surface / firm 60C base)

• Pre-laminated top-covers (mesh, microfiber, antibacterial fabrics)

• Pre-bonded posting sheets (EVA, EVA-rubber, cork/EVA)

• Perforated or grooved comfort layers; branding deboss or printed IDs

• CNC kit-packing from CAD/DXF with left/right mirrors and part labeling

CNC milling guide (typical starting points)

• Tooling: 1- or 2-flute up-cut or straight router bit, Ø 3–6 mm

• Spindle speed: 8,000–18,000 rpm (use lower rpm for softer grades)

• Feed rate: 1,000–3,000 mm/min (adjust to eliminate melting/fuzz)

• Step-over: 40–60% of tool diameter for finishing passes

• Pass depth: 3–6 mm (deeper for firmer grades)

• Tips: Sharp tools, dust extraction, and light air assist improve edge quality. Avoid prolonged dwell to prevent heat marks.

Bonding & finishing

• Surface prep: Light sanding or scuffing; wipe with isopropyl alcohol.

• Adhesives: PU/contact cements, reactive hot-melt, heat-activated films, or PSA where specified.

• Lamination: Heat and press per cover supplier guidance; avoid scorching.

• Edge work: Buff to radius; finish with fine grit for smooth perimeters.

Quality & test methods (available on request)

• Hardness: ASTM D2240 (Shore C)

• Compression set: ISO 815

• Abrasion/wear (for exposed bases): ISO 4649 / DIN 53516

• Tensile/tear (foam): ASTM D3574 / D624 (as applicable)

• Chemicals: RoHS/REACH-friendly formulations available

Care & storage

Store flat, dry, and out of direct UV. Keep in original wrap until use to prevent dust pickup. Clean finished devices with mild soap and water; avoid harsh solvents/bleach.

Frequently asked questions

• Lead time: Standard sheets/blocks ship in about 25 days. Allow +1–2 weeks for PSA, heat-lamination, multi-durometer stacks, or kit-cut sets.

• Samples: Yes—sample kits cover multiple densities, hardnesses, thicknesses, and laminations.

• Soft/firm tuning: Achieved by compounding/expansion; specify target Shore C and density.

• Recyclability: EVA can be recycled where facilities exist; in-plant offcuts are recycled.

• From CAD: Provide CAD/DXF and layout notes; after minor revisions, sample production can usually begin within two weeks.

Ordering checklist

• Target device type (accommodative, semi-rigid, work/safety, sport)

• Hardness and density targets for each layer/zone

• Thickness(es) and laminate stack-up (single/dual/multi-durometer)

• Top-cover material/color and bottom/posting requirements

• Block/sheet sizes or CNC kit-packing with nesting plan

• Adhesive preference (cement, heat-film, PSA)

• Color/branding and labeling needs

• Test/report requirements and delivery timeline

Share your CAD files and the checklist above to receive a tuned specification, machining notes, and a formal quotation.