Working with Styrofoam

Working with Styrofoam has been a common practice in model aviation since at least the 1970s. Cutting wings and tail surfaces was particularly widespread. Wings for motorized models and for both small and large gliders were produced in large numbers and were sometimes sold commercially.

Cutting wings is a team effort. The smooth surfaces are covered with balsa wood or veneer using presses or a vacuum bag, and preparations are made for installing spars and joints. This work is also easier to accomplish as a team. The process is usually completed with a film or glass-fiber coating. Those interested can find information on our modern model aviation website

, for example, on cutting Styrofoam for delta wings:
https://www.modellflugsport.ch/sites/default/files/doku_styroschnitt.pdf

or the construction of large glider wings:
https://www.modellflugsport.ch/sites/default/files/eintraum_aus_schaum.pdf

Around 1980, fuselage spars and other parts were increasingly made of Styrofoam in F3A models.

Ever since three-dimensional data sets have been available for download from the World Wide Web for printing or milling—some of which aren’t exactly cheap—machining Styrofoam blocks with milling robots has become an interesting alternative, especially for mold making. However, the following are suitable for this purpose:

the heavier materials (starting at about 30 kg/m³). A lot of sanding is required before stretching the fabric here, too. It’s a pretty dusty job! Feel free to reach out if you have any questions. Good luck.

Emil Giezendanner,
MFS Editor