Custom Foam Igloo for a Winter-Themed Event

Challenge

When an event planner approached 865FabLab with an unusual challenge — to create a child-sized igloo for a winter-themed birthday party — our team was immediately intrigued. The brief called for a structure roughly 3–4 feet high, 4 feet wide, and featuring a tunnel large enough for a child to crawl through. It also needed to be lightweight, durable, and visually appealing.

Integrated Expertise

This project brought together several of our in-house specialties: CNC Foam Cutting – Precision shaping using rotary axis control Digital Design Collaboration.

Key Product

CNC foam-cutting service

A Fun and Valuable Experience

The igloo project combined engineering precision with creative storytelling, showing how digital fabrication tools can bring imaginative ideas to life. It also opened the door for new applications — from event props and display installations to themed environments and retail scenes.

At 865FabLab, we continue to push the boundaries of custom foam fabrication — producing one-of-a-kind structures, displays, and props that merge creativity, craftsmanship, and technology.

Designing with Collaboration

We modeled the igloo and tunnel in Onshape, our cloud-based CAD software. Using Onshape’s live collaboration feature, we shared a link with the client so they could view and comment on the design in real time. 

This made it possible to tweak proportions and entry dimensions “on the fly,” ensuring that the final product fit perfectly with the intended setup.

Once approved, the EPS foam was machined, sanded, and assembled into its final form — ready for finishing and integration into the event space.

Installation and Display

The finished igloo was designed to be pushed into a large artificial fir tree, creating a magical arctic scene that became the highlight of the party décor. 

The effect was immersive — the igloo appeared to be tucked into a snowy forest, complete with a child-sized tunnel perfect for imaginative play.

The structure measured roughly 3½ feet tall and 4 feet wide, making it easy to transport and install. Its smooth, sealed foam finish provided safety, stability, and a realistic snow-like appearance.