Custom Foam Concrete Formwork

Concrete forms and molds are very popular industry choices because detailing concrete into intricate shapes and designs can be tricky and expensive. Additionally, custom molds used for concrete projects are costly and messy when used incorrectly.

Custom foam forms for concrete, like those manufactured at PFI Advanced Equipment Manufacturing, are a cost-effective way of providing you with the perfect tool to detail and shape your concrete. Unlike concrete molds, custom concrete foam forms are single-use but allow for easy removal once your concrete has set.


No matter what your concrete project is, a custom cut foam framework can provide you with the easiest solution. Expanded polystyrene (EPS) foam is often great at saving you and your company some time and money. For instance, labor costs are much lower with EPS foam than other materials (such as steel or wood), and have a shorter time to both

Custom Cut Concrete Foam Form

set up and remove. Also, our custom foam frameworks will not distort under worksite conditions unlike other types of concrete frameworks.

Trust the experience of PFI to learn about your project and make the proper recommendations. We have been machining and fabricating foam for clients for over 75 years. If you need foam forms for concrete, call PFI Advanced Equipment Manufacturing today:

Machining Concrete Foam Forms

The process for how we machine your custom cut concrete foam forms begins with the engineering phase. First, we work with our customers to understand their concrete foam needs and create a custom foam concrete framework. Using those plans, we use advanced rendering software to create a detailed 3D model of what will become the final product.

We then form approval drawings to confirm, and produce a master cam for the model. This phase ends with production quality control documents being produced. The next phase, production, begins with a CNC hot wire cut of the foam. Afterward, the foam is cut on either the 3-axis or 5-axis milling machine, depending on the project. Depending on whether you are adding a finish to your foam forms, that would then be added onto the form (such as spraying on polyurethane). Finally, the entire process ends with order fulfillment, where we assemble and fit-test the finished product and ensure it is ready for delivery.

Types of Custom Foam Concrete Form Finishes

There are several types of finishes that can be applied to your custom cut concrete foam forms depending on what you would like your finished product to look like. Previously, wood and other materials were used to give a smooth texture to these forms, but they were more costly and harder to use. With EPS foam, we can lend it several finishes to achieve the perfect texture for your project:

  • Uncoated: This is the most cost-effective and standard finish for custom cut concrete foam form. This is a coarse finish.
  • Polyurethane: This gives your form a good amount of smoothness, with some choice between textures to find the best fit for you.
  • Plywood Laminated: We can also attach several types of laminated plywood to the outside of the foam form, adding further structure and texture to your project.

Our expert machinist will help you understand which material(s) are best suited for your concrete form project. Trust PFI Advanced Equipment Manufacturers for your next foam concrete forms. Email us today with your foam concrete wall forms questions and needs:


PFI is well-equipped with different machines to handle almost any custom foam concrete formwork project, including a 3-Axis CNC Milling (used for projects with little depth and/or detailing) and 5-Axis CNC milling (suitable for more complex, detailed, and deep projects). We have a machine envelope of 15 feet x 10 feet x 4 feet, meaning that we are more than capable of manufacturing projects of most sizes. Learn more about the precision CNC cutting tools that PFI uses.

Choose PFI to Create Your Complex Concrete Foam Forms

PFI Advanced Equipment Manufacturing has operated out of Berks County, PA for over 75 years. Our experience makes us foam concrete form experts. We strive for excellence in all of our offered services; we created our Quality Policy to stress we do not compromise on cost or delivery with our products and services.

An additional benefit of choosing PFI as your custom concrete foam form manufacturer is that we are an ISO 9001-2015 and AS9100D certified business. This means that we have demonstrated an exceptional quality control and management system and a dedication to creating the best products possible. This also means that we are constantly looking for methods and practices to further improve our products and that we are resolved to bring our customers the best custom concrete forms possible.

Our services have been requested all over the country, and even internationally. Our complex styrofoam concrete forms are particularly popular in Philadelphia, PA and the surrounding area. If you would like to receive a quote for your custom concrete form project from a local foam fabricating company, choose PFI.