It is no surprise to tell you that foam is a unique and versatile material. You can use it for many applications. For instance, if you work with polyurethane foam, which is the most common type, and want to cut it, you need to follow a few steps. Cutting polyurethane foam is not easy. It requires detailed work – i.e. according to requirements of the desired application.

What do you need to complete the cutting task?

You need a few supplies to carry out the cutting task properly. Before you begin cutting the foam, you need a foam sheet, measurements for your customized cushion, a measuring tape, a yardstick, an electric or sharp carving knife.

These things are important to cut foam for your desired application. Let’s say for your homemade cushions. It is important to use a longer cutting tool such as the blade to make complete cuts.

How to plot your cushions?

Straight lines are important elements for plotting your cushions. Before you start cutting the foam straight, it is mandatory to make an outline. You must do this in the right manner. For this, you can use the adjusted measurements that you had already created.

Next, plot out the dimensions of a rectangle or square on your foam. This represents the width and length of each cushion. You can do this easily by cutting out some newspaper sections to the dimensions of the cushion.

When you put these templates or samples on the polyurethane foam, it will ease the process and allow you to visually access the amount of room leaving between the cushions. At the same time, this saves you from running out of the room.

Moreover, when you do this, it will ensure orienting your cushion in the right manner. You can fit the foam side-by-side in your cushions. On the other hand, if you turn or stack them end-over-end, then they might not fit properly. Next, you need to make some small markings on the foam’s edges to have some rough dimensions for each cushion.

How to mark the foam?

You must mark the form according to the modified measurements that you had done previously. Starting marking the shape of the foam within the boundary area. Use the outer edges, if possible, of the foam to reduce the larger number of cuts.

For instance, if you need rectangular or square cushions, you need two squarely machine-cut sides. Avoid plotting out cushions and don’t share a cutting edge. This method is good for reducing the number of required cuts. However, you can ruin the entire application. So, there is no room for mistakes.

Next, start marking the dimensions of the cushion using a straight edge. Use the marker to make tick marks. Make sure you leave some spaces between the tick marks. You must feel comfortable with the marks. Simply put, they should be easy to work with. We recommend you not to draw complete lines for now – to fix any mistakes committed while measuring the modified dimensions.

Now, check the marks and make sure they are straight enough. Also, you need to ensure the marks are within the boundary area of the cushion. These marks must match the measurements you had already taken.

After confirming and matching the measurements, the next move is to connect the dots through the straight edge. Again, your marker tip must tear into the foam. Finally, these are the line, which you will use to cut along while forming the cushion. Let’s move to the next step.

How to cut the foam?

Before you begin cutting the foam, make sure you work on a flat surface. This means the surface is stable and helps you avoid any damages caused by the inadequate use of the knife on the foam.

If you are using a carving knife, then, it is important to use a gentle sawing motion. We recommend a back-and-forth sawing motion. The blade works through the foam sheet. Also, don’t compress the foam. Don’t make quick cuts through the foam.

Using a softer foam is better because it compresses better and easily during the cutting process. Next, minimize the pressure during the cutting process. It will result in clearer and cleaner edges.

Keep in mind that medium and firm polyurethane foams can resist the pressure during the process of cutting. However, you must not apply extra force. You can get full control over cutting if you compress the foamless. This allows you to make straight cuts, smooth, and flush edges.

On the other hand, if you are using an electric knife, make sure you don’t force the blade of the knife through the polyurethane foam. You may not know but the slower you pass the electric knife through this type of foam, you maintain greater control.

Wrapping up, cutting foam is like cutting baked bread where you don’t need to apply extra force or pressure. No matter what type of application you need the foam for, the key is to cut it the right way. Use the tips given above to accurately cut foam without making any mistakes.

What is the best way to cut foam?

What is the best tool to cut foam board?

While a utility knife is the best cutting tool for thin boards, the best way to cut 2-inch foam board insulation is to use a saw. You can buy a circular saw blade designed for rigid foam, or if you really like to DIY things, you can make your own foam cutting blade using a grinder.

Can you cut foam with a knife?

How do you cut solid foam?

There are only two types of knives you should use to cut foam; both will need to be as sharp as possible, but neither should feature a flat, straight blade. Option one is a serrated carving/bread knife. When using a serrated blade, make smooth and gentle back-and-forth cutting motions through the foam.

How do you cut foam tool?

How do you cut foam with a jigsaw?

In most cases, a simple tool such as a utility blade or X-Acto knife can cut your tool foam. These blades are fairly small, which allows you to cut small shapes without too much trouble. You can also use a heavy-duty foam hot knife for foam cutting.

How do you cut foam smoothly?

Will a jigsaw cut foam board?

How do you cut foam board curves?

A standard-length jigsaw blade won’t cut all the way through the 2″ foam board so you can cut even thin materials. The insulation board will last a long time before it needs replacing.

How do you smooth edges of foam board?

How do you cut an angle on foam board?

How do you cut a foam board with a hot knife?

Will a hot knife cut foam board?

Can you cut foam board to size?

No. Foam core is best cut with a heavy duty utility knife with a big blade. That’s for straight, long cuts. If you need detailed cuts they you’ll have to use an exacto knife-like smaller blade.