Die-cut foam and carved foam are two common foam processing processes, which are widely used in electronics, automotive, packaging and other industries. The following compares and analyzes the characteristics of the two from the aspects of process principles, advantages, disadvantages and applicable scenarios:

１．the principle of the process
Die-cutting foam: Stamping and cutting the foam material through the mold (steel mold, laser mold, etc.), and using the shape of the mold to directly cut out the required contour and structure.
Engraving foam: Using CNC engraving equipment (such as CNC engraving machines), the surface of the foam is engraved by a tool or laser according to a preset program to form complex patterns, text or three-dimensional structures.

２．Advantages:
Die-cut foam, high mass production efficiency, suitable for large-scale standardized processing; High accuracy (error usually ±0.1-0.3mm), suitable for regular shapes; The cost of mold is high, but the cost of mass production is low (amortization of mold cost); Suitable for simple geometries (e.g. round, square, shaped holes, etc.); Higher material utilization and less scrap (depending on mold design);
Engraving foam, single piece or small batch processing is flexible, no need to make molds, saving time for mold preparation; Higher accuracy (error can be controlled within ±0.05mm), complex surfaces, hollows or fine textures can be realized; No tooling costs, but higher equipment depreciation and machining time costs (especially for complex graphics); Suitable for irregular shapes, three-dimensional structures or personalized customization (e.g. LOGO engraving, embossed effects); More debris may be generated during the engraving process, and the material loss is slightly higher;

３．Disadvantages:
Die-cutting foam, the mold needs to be customized, and the mold needs to be reopened when the design is modified, which has a long cycle and high cost; It is difficult to achieve multi-layer nesting, fine hollowing or three-dimensional relief effects; Mold wear may lead to dimensional deviation, and regular maintenance of the mold is required; Affected by the strength of the mold, it is difficult to process thick foam (such as >20mm);
Engraving foam, relying on programming and equipment debugging, complex graphics require a long programming time, not suitable for ultra-large-scale mass production; Complex structures can be realized through hierarchical engraving or three-dimensional path planning, but the equipment performance requirements are high; Relying on the stability of the equipment, long-term machining may have accuracy fluctuations caused by tool wear; Thick foam can be processed, but bottom burrs or collapse may occur when deep engraving;

4. 　Applicable scenarios
   Die-cut foam is more suitable for:
   ａ. Mass production of standardized products (such as mobile phone gaskets, automobile waterproof foam);
   ｂ. Cost-sensitive and simple shape scenarios (such as gaskets, cushions);
   ｃ. Orders that need to be delivered quickly (short production cycle after mold maturity).
   Carved foam is better suited for:
   ａ. Small batch customization requirements (such as sample development, personalized packaging lining);
   ｂ. Complex structure or high-precision requirements (such as special-shaped card slots for electronic components, shockproof pads for medical devices);
   ｃ. Art decoration or brand logo (such as gift box embossed LOGO, exhibition display props).
5. Suggestions for selection
   Cost priority and large quantity: When choosing die-cut foam, it is necessary to evaluate the cost of the mold and the cost-effectiveness of the batch size in advance.
   Precision or customization first: Choose carved foam, suitable for the R&D stage or scenarios that require frequent design adjustments.
   Mixed process: Some companies use a combination of “die-cutting + engraving”, where the basic shape is completed with die-cutting, and then the details are processed through engraving to balance efficiency and precision.

summary
Die-cut foams are known for their scale and economy, while carved foams are known for their flexibility and precision. In practical applications, it is necessary to make comprehensive decisions based on product design complexity, production scale, cost budget and accuracy requirements, and if necessary, the adaptability of the two processes can be tested through proofing.