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Custom Foam Igloo for a Winter-Themed Event

Integrated Expertise

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

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.

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10hrs
DESIGN TIME

2
MATERIALS

6hrs
CUT TIME

What Our Clients Say

Sarah Johnson

Thank you to the team for making this project so easy and within a budget, we look forward to working together soon.

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.

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.

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 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.

Integrated Expertise

This project brought together several of our in-house specialties:
  • CNC Foam Cutting – Precision shaping using rotary axis control
  • Digital Design Collaboration – Onshape live link for real-time client feedback
  • Material Selection – EPS foam for lightweight structural integrity
  • Adhesive and Finishing Knowledge – Surface sealing and durability treatment
  • Creative Integration – Installation into an artificial fir tree for a realistic winter scene

Key Materials & Techniques Used

(Sidebar module – HubSpot Clean Theme)
  • Material: Expanded Polystyrene (EPS) foam blocks
  • Design Platform: Onshape (live collaboration and client feedback)
  • Machine: CNC foam cutter with rotary turntable
  • Process: Rotational hot-wire cutting for dome and tunnel geometry
  • Finish: Sanded, sealed, and smoothed foam surface
  • Integration: Installed into a large artificial fir tree for a winter display
  • Prototype: 2-foot mini igloo built for proof of concept
  • Applications: Event props, display installations, window décor, themed environments

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