CNC Machine carves Styrofoam DeLorean

Owning an enormous CNC router opens up a world of possibilities, but finding projects that truly push its limits can be a thrilling challenge. So, why not aim for the skies — quite literally — and embark on the most 1980s-inspired endeavor imaginable: constructing a full-scale flying Delorean?

Those who have been following [Brian Brocken]'s adventures, perhaps recalling his recent endeavor to revive a welding robot, will be intrigued by his latest pursuit. With a successful revival under his belt, the colossal ABB robot now stands as one of the most impressive CNC routers in existence, thanks to a swift spindle upgrade. As for the flying Delorean, while the fantastical Mr. Fusion modification remains out of reach, [Brian] has opted for more grounded approaches. Although still in its nascent stage, the concept for the airborne vehicle resembles a mammoth quadcopter, concealing motors and propellers beneath its chassis. Naturally, this requires departing from the original stainless steel aesthetic in favor of a lighter alternative: expanded polystyrene foam (EPS).

A fascinating video showcases the fabrication process for much of the body, commencing with large EPS blocks and culminating in meticulously shaped panels amidst a cloud of dust. These components are seamlessly joined with what appears to be ordinary PVA adhesive. Noteworthy modifications include a redesigned "frunk," now featuring louvers to serve as an air intake, with similar treatment anticipated for the rear engine cover. Remarkably, the finished model's weight aligns almost precisely with Fusion 360's projections based on the initial 3D model — a mere 13.9 kg.

[Brian] currently focuses on thrust-testing motors and propellers, sharing intriguing insights into this pivotal phase within his detailed write-up. Undoubtedly, there's ample work remaining on this ambitious project, with countless more clouds of dust yet to be stirred. Nevertheless, the journey ahead promises excitement, and we eagerly anticipate each progressive step.