Renshape?

I've worked with RenShape before. They are available in different density grades per your needs.

Great stuff.

Yes, I always wore a dust mask while machining, cutting and sanding this material. It gets very dusty and I always assume breathing in any dust is not good for you. I would also wear long sleeves and a cap to keep as much of the dust off of my skin and out of my hair and ears. Plus those who introduced it to me advised I do so as well. And I had no health problems from it. 

You might want to check out what Freeman Mfg. and Supply Co has to offer in their Sample Kits. 

They have a web site: freemansupply.com and click on the Sample kit down in the left column.

hope this helps

Thanks for the post.  Looks like I can't get out of wearing the dust mask thing.

I've worked with Renshape in the automotive prototype field, and never had a problem with it other than its dusty and messy, (also, doesn't feel that great when you get it in your sinus's), but no reactions to it,..(believe me, I'm allergic to everything!). I always had more of a problem working with pine, and other nut bareing woods. Can't tell you where to get Ren in smaller quantites. The company I worked for got it in large 3" think slabs. Good luck!  Dave.

Don,

Hope you have been sucessful in your quest for Renshape. If not, let your fingers do the walking. Try shops that cater to prototyping, machining or industrial design. Having worked as a prototype modelmaker, I recall having boxes full of misc. end-cuts to pick and choose from. Hope this helps.