Design Fabrication Lab (dFAB)

dFAB includes dedicated computer workstations with a range of relevant CAD/CAM software, including Rhino, RhinoCAM, Cura, Robotstudio, Mastercam and Robotmaster. Students can prepare files and submit jobs using these workstations. Additionally, select software, including RhinoCAM and Robotstudio, is available for installation on personal computers. A campus VPN connection is required when using this software off-campus.

dFAB maintains two 24"x36" Epilog laser cutters capable of cutting and engraving a wide range of non-ferrous materials. 

Use Procedure

1. CHECK IN: Before your reservation begins, you must check in with a dFAB staff member, provide them with your Andrew ID card, and retrieve your equipment toolkit. The dFAB staff member will then turn on the computer monitor and fume extractors. To utilize the laser cutter, you must swipe your smartphone at the terminal, which will verify your reservation and turn on the machine.
2. PREPARATION: Files should be sufficiently prepared. Materials must be purchased and cut to size prior to your reservation.
3. MATERIAL: Place your material inside the laser equipment. Avoid interference and collisions with fragile equipment parts, such as the laser lens assembly and the honeycomb laser table. Make certain that your material is not sufficiently warped, larger than 1/4″ in thickness, an unapproved material, or improperly cut to size. If your material is warped, you may use masking tape only to correct the insufficiency. If masking tape does not work, then you are not permitted to use the material.
4. POST: Prepare your settings within the Epilog Print Driver. Try to use the recommended settings for your material and process needs. Make sure that the "Auto Focus" option is selected.
5. PRINT: Send your file to the laser equipment. From the laser equipment interface, find and select the green "GO" button. Your laser cutter will now begin working on your file.
   1. TO PAUSE: Find and select the red "STOP" button located on the laser equipment interface and press it once. Your file will continue cutting until it reaches an endpoint in its defining line geometry; then the laser lens assembly will freeze and stop firing the laser. You may now safely open the laser equipment lid. You may not remove and/or move your material. To continue your job, close the lid, then find and select the green "GO" button on the laser equipment interface.
   2. TO STOP: Find and select the red "STOP" button located on the laser equipment interface and press it. Your file will continue cutting until it reaches an endpoint in its defining line geometry; then the laser lens assembly will freeze and stop firing the laser. Find and select the red "RESET" button on the equipment interface and the laser will return to its origin. After this occurs, you can now open the equipment lid, move/remove your material, or send another job.
   3. EMERGENCY: Find and depress the "EMERGENCY STOP" button located on the front, righthand side of the laser equipment. Contact a dFAB staff member immediately.
6. CLEAN: Within the final five (5) minutes of your equipment reservation time, you must terminate all equipment processes and begin cleaning. Use a vacuum to clean the honeycomb laser table. Avoid strong collisions with the table or laser lens assembly. Remove all scrap and debris and place in available trash cans. Do not overfill the trash cans; notify a dFAB staff member and a new trash can will be provided.
7. CHECK OUT: Turn off the computer monitor with the remote button located in your equipment toolkit. Return the equipment toolkit with all items intact and accounted for. After a dFAB staff member reviews and approves the equipment and area sufficiency, your Andrew ID card will be returned to your possession.

There are numerous additive prototyping tools available for dFAB users. These include fuse deposition and powder printing technologies. Specific equipment details are listed below:

Ultimaker S3 Printer Maximum Build Size: 8.6in x 7.1in x 7.5in Filament Thickness: 2.85mm Layer Resolution: 0.06-0.3mm Minimum Wall Thickness: 1mm Print Color: Various (see dFAB staff member) User Pricing: See dFAB staff member	Image
Ultimaker S5 Printer Maximum Build Size: 12.6in x 9.1in x 11.4in Filament Thickness: 2.85mm Layer Resolution: 0.06-0.3mm Minimum Wall Thickness: 1mm Print Color: Various (see dFAB staff member) User Pricing: See dFAB staff member	Image
Bambu Lab Printer Maximum Build Size: 9.5in x 9.5in x 9.5in Filament Thickness: 1.75mm Layer Resolution: 0.08-0.28mm Minimum Wall Thickness: 1mm Print Color: Various (see dFAB staff member) User Pricing: See dFAB staff member	Image
ProJet 360 Powder Printer Maximum Build Size: 10in x 8in x 8in Layer Resolution: 0.004in Minimum Wall Thickness: 0.125in Minimum Column Diameter: 0.250in Print Color: White User Pricing: $0.09/cu.cm. (powder) + $0.25/mL (binder) + $4.00 printhead fee	Image

Use Procedure

1. PREPARATION: You must sufficiently prepare a 3D model using your desired software. dFAB staff will provide minimal troubleshooting assistance. dFAB staff will not provide in-depth instruction or training on 3D modeling software outside of course instruction. Ensure that your 3D model meets the minimum wall thickness requirements as indicated in Policy C.
2. EXPORT: Export your 3D models as a stereo-lithography (STL) file type in millimeters (mm) units. If the file includes multiple parts, each part should be exported separately as its own file.
3. CHECK: Open your STL file in Rhinoceros 3D. Type "MESH REPAIR" into the command prompt and press "ENTER." A new window will appear indicating problem areas, if any. If the window indicates "This is a Good Mesh," proceed to Step 5.
4. TROUBLESHOOTING: If your file reads as a "Bad Mesh," then it is not capable of 3D printing and requires troubleshooting. Visit the dFAB website and browse available 3D printing tutorials for assistance.
5. SUBMISSION: Click the "3D Printer Submission Form" link and closely follow the instructions to submit the file.
6. REVIEW: A dFAB staff member will review your file and confirm whether it will print on the desired machine. If rejected by the machine’s software, you will need to make the necessary changes to the STL file and resubmit.
7. PICK UP: You will receive an email when your part is ready for pick up or if there are any additional issues with your file during the print process.

A four-axis CNT Motion industrial CNC router supports a range of fabrication projects, from models to artifacts, prototypes and components.

Machine Specifications:

• Work Zone Size: ≤ 8′x4′
• Maximum Material Thickness: 5″
• Available Milling Tool Diameter: 0.25″, 0.375″, 0.5″, 0.75″ (carbide and high-speed steel available for purchase) 
• Milling Tool Diameter: 0.0625″, 0.125 (various compression spiral tools (carbide) available) 
• Drilling Tool Diameter: 0.03mm, 5mm, 6mm, 8mm (carbide)
• Miscellaneous Milling Tools: Engraving, compression, lollipop
• Software Workflows Supported: RhinoCAM, Mastercam, WinCNC, Rhinoceros

Important Notes:

• Approved Materials: Plastics, lumber, foam
• Prohibited Materials: Homasote, drywall, steel (ferrous metals)
• See dFAB manager regarding milling operations involving aluminum and plastics.
• The CNC equipment is for research and learning purposes only. Crafts, gifts, Spring Carnival projects and "Buggy" are not permitted on this equipment.
• Files must be prepared before reserving equipment.
• Dust collection systems must be turned "ON." Protective eyewear is required. Dust masks and ear protection are provided and highly recommended. Closed-toe shoes are also recommended.
• There is a risk of fire when using this equipment. As such, you are required to stay in the CNC room/area while your job is running to keep an eye on the process. In case of fire, stop the job and notify a dFAB staff member immediately.

Use Procedure

1. RESERVATIONS: Students must show a dFAB staff member a ready RhinoCAM file before scheduling a reservation time on the machine. Only a dFAB staff member can place and cancel CNC router reservation times.
2. CHECK IN: Before your reservation begins, you must check in with a dFAB staff member, provide them with your Andrew ID card, and retrieve your equipment toolkit. You may now use the equipment.
3. PREPARATION: Your CNC files must be sufficiently prepared within fifteen (15) minutes of your reservation start rime.
4. FINAL APPROVAL: A dFAB staff member will review and simulate your file prior to you using the equipment. 
5. POST: Post your file to the "CNC Router Temp folder" on the dFAB server in a folder named with your Andrew ID: dFAB DropBox > CNC Router/ Program/ Year/ AndrewID/ Post). dFAB staff must edit the code in your post if your material/stock is less than or equal to 4′ length by 4′ width.
6. FASTENING: Set your material on the CNC worktable. Ensure the material will hold properly by turning on the vacuum table via the WinCNC application interface. For material larger than 4′ length by 4′ width, select the "VAC FULL" button in the WinCNC interface (VAC FULL = 8′x4′ table vacuum). For material smaller than or equal to 4′ length by 4′ width, select the "VAC FRONT" button in the WinCNC interface (VAC FRONT = 4′x4′ front table vacuum). If your material does not hold, you may use double-sided tape (provided in your equipment toolkit) or brace your material with other scrap material pieces. Bracing material must be less than or equal in thickness and less dense (i.e. foam is less dense than plywood). Note: You are not permitted to screw your material to the CNC worktable!
7. PREVIEW: Preview your file in the WinCNC interface by opening your post file and selecting the "Preview" button. Your toolpaths will appear in the WinCNC interface preview pane. Confirm that your toolpaths are properly aligned with the origin point.
8. SIMULATE: Simulate your post within the WinCNC interface by loading your post file, which you opened in the previous step. Select the "Simulate" button. A new window will appear with the estimated completion time displayed in the lower right-hand corner.
   1. Note: You must adhere to your appointment time! dFAB staff will not approve extended equipment time for file completion. Your equipment usage ends fifteen (15) minutes prior to the end of your reservation to allow time for clean-up.
9. DUST COLLECTOR: Turn the dust collector "ON" before your file begins. This manually activated button is located on the CNC room wall. Green = "ON" and Red = "OFF."
   1. SAFETY: You are required to wear protective eyewear while in the CNC room and while the CNC router is in motion. Protective eyewear is available in your equipment toolkit. Your toolkit also includes additional safety gear (a breathing mask and ear protection) which are optional while in the CNC room.
10. GO: After all previous tasks are completed, select the "Start" button in the WinCNC interface, or press the "ENTER" key twice to begin your CNC file.
    1. PAUSE: Select the large gray "PAUSE" button in the WinCNC interface. The CNC equipment will pause, but the spindle and vacuum table will continue to run. You may approach the equipment and perform necessary tasks as long as you are wearing protective eyewear, all loose clothing (scarves, long-sleeves) and hair is restrained, and you remain aware of moving parts.
    2. STOP: Select the large red "ABORT" button in the WinCNC interface. The CNC equipment will retract to a safe "Z" clearance height and remain stationary on the "X" and "Y." The spindle will remain on! To continue safely using the equipment, you must turn the spindle "OFF" by selecting the small gray "SPINDLE" button in the WinCNC interface.
    3. EMERGENCY: Immediately remove yourself from danger. 
       1. LEAVE THE ROOM and do not return until it is safe to do so. Allow the equipment to "run its course" if necessary; this might include collisions, material interference and tool breakage. However, your safety is of immediate and prominent concern. 
       2. ONCE THE AREA IS SAFE, press the red "E-STOP" button located on the front top right-hand corner of the blue controller box. Contact a dFAB staff member immediately. Alternately, pull the pink/orange "E-STOP cord" running around the entire machine. This method is less preferred, since it will put you in close proximity to the equipment.
11. CLEAN: Within the final fifteen (15) minutes of your equipment reservation time, you must terminate any existing equipment processes and begin cleaning. After all processes have terminated, you must return the equipment and area back to its original state. Scrap materials must be taken to the dumpster located behind MMCH. Trashcans are available upon request and must be emptied before they are returned. Brooms, dust collector hoses and air tools for dust and debris cleaning are provided in the CNC room. Users are required to wear breathing masks while cleaning the CNC room. dFAB staff is not required to assist any student with clean-up or large scrap removal. Please plan accordingly.
12. CHECK OUT: Return the equipment toolkit with all items intact and accounted for. After a dFAB staff member reviews and approves the equipment and area sufficiency, your Andrew ID card will be returned to your possession.

Procedure

1. CHECK IN: Before your reservation begins, you must check-in with a dFAB staff member. Only after first checking in may you utilize the equipment.
    
2. PREPARATION: Molds must be completely dry and free of all particulates. Materials must be purchased and cut-to-size within fifteen (15) minutes of your reservation start time.
    
3. START UP: Turn the equipment "on" by pulling down on the circuit switch on the rear wall of the vacuum forming area.
    
4. WARM UP: Using the turn-dial knobs on the vacuum former, adjust to the desired heat settings and locations. Each knob controls a different heating element area, and some may be unnecessary depending on the size of your vacuum forming window. Also, too much heat can cause your material to boil/bubble. Heating up slowly and at lower temperatures is highly recommended.
    
5. WINDOW: Install necessary window size for your specific workflow. The re-sizing windows are easily removed/installed with hand tightened/loosened nuts and bolts. The vacuum former includes two window sizes: 24″ x 24″ (vac form material must be cut-to-size at 26″ x 26″ minimum); and 11″ x 11″ (vac form material must be cut-to-size at 12″ x 12″ minimum). Alternately, you can opt to use the equipment without re-sizing windows, and utilize the full bed: 25″ x 25″ (vac form material must be cut-to-size at 27″ x 27″ minimum).
    
6. PLACEMENT: Pull forward on the vacuum former arm on the right side of the equipment. This will raise the bed within the vacuum chamber. Place your mold within the vacuum forming window and ensure 3/8″ to 1/2″ of clearance from the edges. Make sure the steel screen mesh is sitting underneath the mold. Lower the bed slowly by pushing the vacuum former arm backward. Unlock the window frame and "sandwich" your thermo-plastic material within the re-sizing windows. Lock the window frame with your thermo-plastic properly aligned and placed. Pull the heating element frame over top of your framing window.
    
7. STATES: Your material will go through three (3) states of change. First, the material will deform unevenly and warp upward. Second, the material will begin to level off completely and become very glossy. Lastly, the material will begin to sag downward into the vacuum chamber. During the final stage, your material will become very "sheet-like" and malleable. If you bump the machine lightly with your hand you will see the material bounce somewhat. You can also push the heating elements back and lightly touch or press on your material. Make sure the edges are malleable enough to pull down and around your mold.
    
8. VACUUM: When your material reaches a sufficiently malleable state, casually push the heating elements backward to terminate the heating process. Pull the vacuum former arm forward to raise your mold and plastic material up through the window. Find and flip the rocker switch labeled "pump" on the equipment to turn the vacuum "on" and pull your plastic down into/onto your mold. If you notice limited change, use your body weight to push down on the window frame handles in the front of the machine to assist with the vacuum’s pull and ensure a complete seal in the vacuum chamber.
    
9. COOL: When your plastic reaches a point where it can be handled safely, turn the pump "off." Alternately, you can reverse the air-flow in the vacuum chamber by finding the toggle labeled "pressure" and pushing it downward. This will assist with de-molding your plastic from the mold. Please note that the pressure toggle should be pressed completely downward or left in its normal position; there is no "in-between" state.
    
10. REMOVE: Unlock and lift the framing window and remove your part.
     
11. SHUT DOWN: Clean and remove any debris or scrap left in/on the equipment/area. Turn all heating knobs back to the "off" position. Turn the equipment "off" by returning the circuit switch back to its upward position. Leave re-sizing windows as they are.
     
12. EMERGENCY: Return the heating elements back to their home position. Contact a dFAB staff member immediately.

Equipment Specifications

Window Sizes: 11″ x 11″; 24″ x 24″; 26″ x 26″
Maximum Depth: 14″
Sheet Sizing: 12″ x 12″; 25″ x 25″; 27″ x 27"
Sheet Thickness: <0.25″

Important Notes

• The vacuum forming equipment is for academic research and coursework ONLY. "Buggy" parts and fabrication are not permitted on this equipment.
• Ensure that all sealed and/or laminated molds are dry before vacuum forming, such as clear coats, shellac, wood glue, latex paints, etc.

The Design Fabrication Lab maintains a growing suite of ABB industrial robots and end-of-arm tooling to support faculty research and advanced-level coursework. Robots are integrated to support multi-axis milling, 3d pellet printing, incremental metal forming, and pick and place. Students interested in using the dFAB Lab Robotics Arms must have completed the ITAR (Intro To Architectural Robotics) course, and/or provide proof of equipment and software experience and skills to the dFAB Lab Manager and teaching ITAR Faculty member before being approved to use the equipment.

Robotic Arms

ABB IRB-6640 
ABB IRB-4400
ABB IRB-1600
ABB IRB-120 on Rolling Cart

Policy and Procedures

1. ABB IRB-4400 & IRB-6640: Robotic Cell

   a. CLEAN UP: All mess, debris, scrap, stock, tools, material, must be cleaned and returned to original state

   b. ROOM ACCESS: All entry into room must remain closed and locked except when necessary for project execution or preparation

   c. TOOLS: All hand tools tagged with Blue Spray Paint & hosted in RobLab, never leave the room

   d. DESKS: White Tables are for Computer/Clean Work ONLY

   e. STORAGE: Project/Material Storage must be labeled. (3) day Storage Limit unless otherwise discussed

   f. DOCUMENTATION: All Robotic research should be documented and stored within the dFAB Server (dFABSERVER1/DropBox – Robotics)

   g. APPOINTMENTS: Equipment Reservations allow for Preparation, Testing, Research, Computer-Use, Operation and Robotic Related Work-Flows. Users must be mindful of limited time and shared space issues

   h. OPERATION: Should the Operation require, all other Users must retreat to a safe work-zone and/or leave the space if deemed necessary by Operational Status. All Users yield to Reservation/Appointment Owner

2. ABB IRB-4400 & IRB-6640: Work-Zones

   a. ALL WORK-ZONES: Work-Zones are provided for various Robotic Work-Flows. With advance notification and permission, Users may alter position and affix custom jigs, tools or objects to ROBLab mounting Surfaces. Users are expected to breakdown, clean, and return Work-Zones to their original state. Altered Work-Zones are subject to change and movement throughout the semester

   b. 3D ENVIRONMENT: Users are responsible for ensuring proper development and setup of 3D Environmental requirements for successful RAPID Code Generation/Simulation

   c. ROLLING VACUUM TABLE: Rolling Vacuum Table is for Robotic Work-Flows ONLY. Vacuum Table utilization must be discussed in advance, prior to Reservation/Appointment. With approval, Past and/or Current Projects, Set-Ups, Jigs, etc. will be removed for Reserved User Appointments

   d. STEEL TABLE: Steel Table is for Robotic Work-Flows ONLY. Steel Table utilization must be discussed in advance, prior to Reservation/Appointment. With approval, Past and/or Current Projects, Set-Ups, Jigs, etc. will be removed for Reserved User Appointments

   e. WALL-MOUNTS: Wall-Mount Jigs are for Robotic Work-Flows ONLY. Wall Mount Jig utilization must be discussed in advance, prior to Reservation/Appointment. With approval, Past and/or Current Projects, Set-Ups, Jigs, etc. will be removed for Reserved User Appointments

   f. ROTARY TABLE: Rotary Vacuum Table is for Robotic Work-Flows ONLY. Rotary Vacuum Table utilization must be discussed in advance, prior to Reservation/Appointment. With approval, Past and/or Current Projects, Set-Ups, Jigs, etc. will be removed for Reserved User Appointments

   g. DESKS: White Desks are for Computer/Clean Work ONLY

   h. WORK-TABLE: Work Tables are positioned throughout the lab for Fabrication related work-flow. Work-Table usage must be approved beforehand. Users must label their work and clean-up afterward

3. ABB IRB-4400 & IRB-6640 : Manipulators, External Devices, Controllers & TeachPendants

   a. DO NOT:

   - Push ANY buttons on the robot

   - Unplug ANY connections on the robot or ATI Robot-Side interface

   - Climb or physically engage robot

   - Place non-toolside objects on the robot

   - Store/place objects on the Track

   b. CONTROLLERS:

   - should remain ON

   - Cases will not be opened by User

   c. TOOL PLATES:

   - All ATI tool plates are to be dismounted and returned to default configuration (user custom tools removed).

   d. TEACH PENDANT (TP):

   - TP is to be treated with GREAT CARE. User is subject to Fines and/or Fees related to TP misuse

   - TP menu user access is restricted to the following:

   - HotEdit, I/O’s, Jogging, Program Editor, Program Data, Production Window

   - User Modules should be uploaded to the USER MODULES folder

   System Modules and other core files are not to be altered nor delete 

4. ABB IRB-4400 & IRB-6640 : Operation

   a. UNIVERSAL:

   - All Operations will be simulated prior to execution

   - All Users will be aware of non-simulated variables, dress pack, work surface etc.

   - Space will be cleared of debris and extraneous material, taking into account all moving parts of the manipulator not just the TCP

   - Operator will be sober, awake and attentive at all times of operation

   - Operator may be accompanied by other users, teammates, and robotic authorized personnel

   - Robot will not physically engage living organisms.

   b. MANUAL MODE:

   - Users will remain clear of working perimeter

   - Operator may be accompanied by other Users and Robotic Authorized Personnel.

   - Operator will hold TP properly while motors on

   - Users should not interfere with environment while motors on

   c. AUTO MODE:

   - All Non-Essential Personnel are to leave the area

   - All Essential Personnel are to be on the SAFE side of the light curtain with required Safety Equipment

   - Speed will not be permitted to exceed 2000mm/s at all times for any operation

   d. TOOLING: When using Dangerous Tooling Attachments (i.e. Spindle, WireSaw, Plasma, etc.)

   - All Non-Essential Personnel are to leave the room entirely

   - All Essential Personnel are to be on the SAFE side of the light curtain with Safety Equipment

   - Operator will be accompanied by at least one authorized user

   - Stock is to be properly secured

   - Work with particular tools will only occur in designated work zones

   e. TOOLING: When using Less Dangerous Tooling Attachments (i.e. Gripper, Hot-Wire, Sensory Apparatus etc.)

   - Follow Protocol for Mode of Operation

   f. SPECIAL CASES: Live Command, Indeterminate Operation

   - Modules that may produce Non-Simulative Motion Variability are to only be executed under direct supervision by Admin or Advanced User. Auto-Mode rules apply. Active tooling with indeterminate operation should be executed with extreme caution and supervision, and should be preceded with rigorous testing and simulation.

The lab stocks a few different wood sheet products that are commonly used for CNC routing.

MDF / ULDF

Medium-density fiberboard (MDF) is an engineered wood product formed by breaking down hardwood or softwood residuals into wood fibers, often in a defibrator. The fibers are combined with wax and a resin binder and formed into panels by applying high temperature and pressure. MDF is commonly denser than plywood. dFAB typically stocks ultra-light density fiberboard (ULDF), which allows for quicker, safer and more efficient machining. This material works best for scale modeling and prototyping because of its forgiving nature towards bits. This material is strong and easy to machine and sand. dFAB stocks ULDF in 1/2 inch and 3/4 inch nominal thicknesses.

Plywood

Plywood is made from laminations of veneer. It is light but strong and has many other good properties. Plywood is used to make longboards (skateboard), giving it a strong yet flexy ride. It is also used for making model aircraft, often in very thin grades with many laminations. This wood product is strong and lightweight while maintaining its beauty. It is suitable for any woodworking project. dFAB stocks birch, revolution and AC Plywood in 1/4 inch, 1/2 inch and 3/4 inch nominal thicknesses.

dFAB stocks various plastics, available for purchase.

Acrylic

Acrylic is possibly the most commonly used plastic and is often referred to as plexiglass. Acrylic comes in various tints and colors and is suitable for the laser cutter. Acrylic is either extruded or cast. While cast acrylic offers better machinability and laser cutting, extruded acrylic is typically more cost effective. Acrylic is typically laser cut to create a more professional finished model. dFAB stocks acrylic in clear, white and black in 1/32 inch, 1/16 inch, 1/8 inch and 1/4 inch nominal thicknesses.

PETG

Polyethylene terephthalate glycol (PETG) is a thin, transparent, thermoplastic sheet used for vacuum forming. It is typically more impact resistant and cost effective than acrylic. Its malleability offers deep draws for vacuum forming. dFAB stocks PETG in 1/32 inch and 1/16 inch nominal thicknesses.

Polystyrene

Polystyrene (PS) is a thin, economical plastic used for vacuum forming. It is used for producing plastic model assembly kits, plastic cutlery, CD “jewel” cases, smoke detector housings, license plate frames and many other objects where a fairly rigid, economical plastic is desired. Production methods include stamping and injection molding. This material is more commonly used for vacuum forming because of its malleability. dFAB stocks PS in 1/32 inch and 1/16 inch nominal thicknesses.

Building insulation foam is a commonly used, affordable material that yields acceptable results for site models and form prototypes. 

XPS Foam

Extruded polystyrene foam (XPS) consists of closed cells, offers improved surface roughness and has higher stiffness and reduced thermal conductivity. Typically offered in pink, blue or green, it has adopted the name "pink foam." This material is typically used for milling because of its forgiving nature towards bits and equipment as well as its machinability. These materials cannot be spray painted or vacuum formed because they will melt. There are other more expensive options that allow for easy sanding, painting, resin coats and vacuum forming such as polyurethane foam, however dFAB does not have this material readily available. dFAB stocks XPS foam in 2 inch nominal thickness.