How to Cut Foam Board
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Cutting Foam Board Insulation
I use foam for a rather boring purpose. I buy large sheets of styrofoam board and cut it up to protect items I ship. Sometimes this means reinforcing box walls, or just protecting fragile items.
I've tried using a variety of tools to cut foam: box cutters, a hot knife, soldering iron, woodburner tool.... Here's what I've found out about how to cut foam board...
Above photo Creative Commons licensed for use: Photo is by Mark Olsen
Contents at a Glance
The Best Hot Wire Cutter for Foam
Ideal for craft projects, architects, and for any other job that requires PRECISION
Proxxon 37080 Hot Wire Cutter THERMOCUT
Amazon Price: $91.75 (as of 05/31/2012)
This hotwire cutter looks like the best deal. It has all positive reviews and even customer pictures of their final foam sculpture!
I haven't tried this one, but I thought that I would first recommend the tool that seems to be best for making exact, measured cuts. (Something I haven't been able to do with a box cutter or hot knife.)
Utility Knife (Box Cutter) does the job, but causes a bit of a mess!
(Not recommended for precision.)
Sparco Products 15851 PVC Grip Knife, Stainless Steel Chamber, Yellow/Black
Amazon Price: $0.95 (as of 05/31/2012)
This type of construction knife does a good job because the blade can slide out as long as you need it. It you cut the foam slowly, at an angle, you might manage to do it with minimal mess.... but I usually end up with the floor covered with white dots, AND the edge of what I cut is ragged :(
A Hot Knife is Another Tool for Cutting Foam
Not for making small cuts, but great for big projects.
Electric Hot Knife
Amazon Price: $25.99 (as of 05/31/2012)
I've used this one, but the "knife" is much thicker than a wire, so it doesn't make small cuts in the foam. This knife would probably work best for cutting large pieces of foam, or for making holes or cavities in it. Check out the below video, which does a good job of showing how it works.
I wouldn't recommend this one for jobs that require precise cuts.
The main advantage over using a utility knife is that you don't get all of the tiny foam pieces breaking off and going all over. The disadvantage is that the melted foam smells, and so you'll need ventilation.
You can also use a soldering iron or a woodworking tool
A cheap tool for cutting or making holes in styrofoam
Dremel 1550 T2 Versa Tip Multipurpose Tool Kit
Amazon Price: $19.94 (as of 05/31/2012)
We have used a tool like this one to make holes in foam and cut it.
Product Description:
"Multipurpose tool for wood burning, soldering, hot knife cutting of styrofoam and plastics, cutting and fusing rope. By simply switching tips, the tool can be used for wood burning, leather crafting, stencil cutting, soldering, or hot-knife cutting of foam, plastics and rope. "
Foam Wire Cutters on Ebay
Many other models to choose from....
More Information on Cutting Foam
DIY Hot Wire Cutter, Industrial Large Foam Cutting Machines, and More
- How to Cut Foam for Sewing Projects | eHow.com
- This article suggests using an electric knife (the kind used for cutting bread) for cutting furniture foam.
- Hot-wire foam cutter - Wikipedia, the free encyclopedia
- Includes a list of the types of foam that can be cut with a wire foam cutter.
- Hot Wire Foam Cutting
- This article is about my adventures in foam cutting with a hot wire method. Instructions for a do-it-yourself homebuilt foam turning lathe machine.
- Building a Hot Wire Foam Cutter
- Building a Hot Wire Foam Cutter Hot wire foam cutters work by heating special wire to the point where it vaporize foam it is brought in contact with. It is a technique commonly used commercially and hot wire foam cutters are available for any where to several hundred to several thousand dollars.
- 3D CNC Foam Cutting Machines and Equipment | 3D Foam Cutters & CNC Foam Carving Equipment | Cut Foam | Streamline Automation
- Streamline Automation leads the CNC foam cutting market with the FROG3D® line of hot wire foam cutters and 3D CNC foam carving equipment used to cut foam and create 3D foam sculptures, foam props, foam signs, themeing projects, architectural moldings and concrete molds.
- CNC Foam Cutting : Foam Cutters : Foam Fabricating : Foam Fabrication : Polyurethane Foams : Foam Packaging : Foam Packing : Foam Machine : Cut Foam
- Foam Cutting Machinery, Inc. will help you find the best CNC Foam Cutting, Foam Cutters, Foam Fabricating, Foam Fabrication, Polyurethane Foams, Foam Packaging, Foam Packing, Foam Machine and Cut Foam.
Your Comments:
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kraptain
May 18, 2011 @ 5:42 pm | delete
- I need to cut / burn a whole bunch of 2" holes for my aquaponic system rafts.This would be going thru 2" Dow Blue Board. I have used hole saws in reverse, (so-so results, no smooth edge) and even tried heating up an empty can heated over charcoal. Work well (perfect holes, clean edges) but could only do a few holes before re heating or switching to another can.
Is there a way to make a hot knife that cuts round plugs?
Thanks for your help!
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hotbrain
May 21, 2011 @ 3:45 pm | delete
- Good question... I haven't found anything that will do a 2" diameter. The largest I found was 1/2", using this machine: http://www.thewebcutter.com/RX-80HA.html
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Ben
Dec 4, 2011 @ 3:56 pm | delete
- use a lennox diamond holesaw bit.. very smooth and cuts perfect holes
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MelissaInTheSky
Apr 21, 2011 @ 1:27 pm | delete
- I use foamcore often. Very helpful info. Thanks!
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I use this glue gun for glueing foam to cardboard
Dremel 1200-01 Glue Gun Kit
Amazon Price: (as of 05/31/2012)
Gluing two pieces of foam board together doesn't work so well, because the hot glue melts the foam somewhat. However, I've found that if I glue the foam to cardboard, I use the cardboard in between the foam pieces. That is, I glue a piece of foam to each side of the cardboard.
And, despite the negative Amazon reviews on this Dremel glue gun, I love this glue gun. For me, it works quite well and is a big improvement over the cheap $5 glue gun I used to use!
Gluing Styrofoam to inside a box creates an extra strong box! I mostly use foam for packaging things!
These Foam Sheets have many uses!
Peel & Stick Foam Sheets 5.9-Inch-by-4.43-Inch 65-Pack, Rainbow Colors
Amazon Price: $4.96 (as of 05/31/2012)
