[Video] Large Scale Mold Making - Part I

Step 2 Foam and Cutting

We're using a high density insulation foam. If you have the option, get foam that is not scored - ours is scored, and it breaks somewhat easily along the scores.

This foam is some tough stuff. Our electric carving knife has some trouble cutting through - but a jigsaw does work ;) Our preferred method? A jet of 60,000psi water.

We had 37 sections (plus 4 additional sections to create NACA ducts) machine cut on a Waterjet. We used a company in Orlando called Crossroads Unlimited. In fact, we have used them for the past three years. They have a large Waterjet (72" x 144" cutting area) capable of doing abrasives. I highly recommend them if you're in the area.

Please keep in mind the cost scale. Each sheet costs $13. Luckily more than one section could fit on one sheet.