Hello. I am in the process of making a series of decorative wooden boxes to store and display optical equipment. I am interested in any good ideas to improve my ability to cleanly cut foam inserts to specific complex shapes to accomodate these items. This is the sofer sort of foam rather than the firm foam like styrofoam that cuts so well with a hot wire.
In the past, I’ve tried a variety of methods including cutting the foam in layers with a utility knife, sawing, etc. Unfortunately, things never come out as crisp and clean as I would like. I’ve also heard tales of freezing the foam to stiffen it and make the cutting cleaner, etc.
Any great ideas for accomplishing this for those of us that don’t have a CNC foam cutting machine….
Thanks in advance.
Rick
Replies
I've had some success using an electric kitchen knife.
If you're going to do a lot of them, a knife band for your band saw might be just the ticket.
Pete
Astro ,
We make a lot of cushions and some are irregular shapes as well as other items we cover with fabrics . For the larger pieces I use the band saw for most pieces . An electric carving knife works quite nicely as well .
Bosch makes a foam cutting saw that looks like a sabre saw with a tall foot platform and long blades , this is typically what professional upholstery people use , and it does a beautiful job , it seems like the price is around $300 give or take .
good luck dusty
My dad was an upholsterer and in the '60s, when my mom decided that she really didn't like the electric carving knife (and some needling from dad), he started using it at work and it was great. I have also seen them used on TV recently and while the Bosch unit probably works well, if this is mmore hobby than professional use, the carving knife may be more practical.
"I cut this piece four times and it's still too short."
I just the other day cut some cushion type foam with a 3/16" X 10TPI Bandsaw blade and it worked wonderfully. Made some knee raisers for the bed( Bad Back ) and some lumbar supports for the car seat. Start slowly on the initial part of the cut but once the blade is 1/4" into the foam it cuts great. Another thing that helps is to set the foam on a piece of craft paper so it slides easily on the bandsaw table.
Work Safe, Count to 10 when your done for the day !!
Bruce S.
Rick, Google up 'steel rule and die' Read the first link.
They can make you a small flexible punch to your exact requirements It looks like a razor sharpened band saw blade.
(minus the teeth)formed (Bent) to exactly the shape you'll need.
It is attached to a flat block. In use, The material (Foam is stacked in layers on a wooden board and punched or pressed by a vise , clamp or foot operated punch.
This is how for years they were used to make jigsaw puzzles.
Steinmetz.
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