Foam Cutting
As you may know, foams are categorized into three types: EVA, polyethylene, and polystyrene (Styrofoam). They are primarily used for shock absorption, and to prevent the transmission of sound and heat. Additionally, foam sheets are used for filtration, product packaging, and as underlayment in building construction. Foam cutting is the first stage in manufacturing foam products after the foam is produced. Since foam is a soft and flexible material, cutting it can be both easy and delicate, especially for specific cases, requiring the use of specialized foam cutting machines. For simple cuts, scissors, blades, or cutters can be used, but for larger cuts, specialized tools and machinery are required.
Types of Foam Cutting Methods
Manual Foam Cutting
Manual foam cutting uses simple tools like scissors, cutters, cookie cutters, and even dental floss.
- For thin and flexible foams like those used in flower making and crafts, heavy-duty scissors are necessary. You can draw your desired shape on the foam and then cut it with scissors. Aim for long, smooth cuts.
- For simple cuts on thin foam, you can also use a cutter or blade. Here’s a tip: before cutting, rub the blade of the cutter with a candle. This helps the blade slide smoothly over the foam and prevents the foam from sticking to the cutter.
- Using a cutter or metal cookie cutter, you can cut foam up to 12 mm thick. Place the foam on a flat surface and press the cutter onto the foam with some pressure to cut through.
- Using dental floss to cut thin foam is an interesting technique! Cut a long piece of dental floss, place it on the work surface, and lay the foam sheet over it. Position the floss where you want to cut. Hold the foam with one hand and pull the floss toward you with the other. This method is best for simple cuts. If you need to cut multiple foam sheets, it’s best to cut them separately for cleaner results.
Electric Cutting Tools
- For cutting thicker foams (4 to 10 cm), an electric knife can be used. Use the thinnest blade on the knife for straight or curved cuts. Glide slowly through the foam for a clean cut. If cutting very thin foam, avoid pressing too hard with the electric knife.
- For regular foam cutting in large quantities, consider using a specialized electric foam-cutting saw.
Laser Cutting for Foam
Unlike PVC, for laser cutting and engraving EVA foam, the materials must be safe. However, processing foam with laser cutting typically results in slight discoloration at the edges and a tacky surface due to engraving. The only type of laser recommended for working with EVA foam is CO2. Precautions must also be taken to prevent fire and flame hazards when working with this material. The video shows an example of laser cutting on EVA foam.
Foam Cutting Machines
It’s good to know that foam sheets are used both as final products and as supplementary materials in product processing. Therefore, they are cut into various shapes and thicknesses using laser or thermal foam-cutting machines. For precision tasks, such as part manufacturing, CNC cutting machines are used. The CNC foam cutting machine uses a blade to cut different types of foam, including EVA and sponge foam. This machine can cut various shapes without the need for molds, using CAD designs.
Denafoam’s design unit provides services related to the foam industry, such as cutting, foam lamination, and die-cutting, using the latest technology and advanced equipment to design and produce various necessary and complementary products for different industries, including medical, flower making, automotive, glass, ceramics, and more.
