Cutting Foam





Introduction: Cutting Foam

This Instructable is part of a collection of I'bles on how to make foam weapons. Check it out here!

Step 1: Craft Foam

If you're cutting thin craft foam, plain old scissors work pretty well for this job, but if you're a perfectionist, this method gets you slightly cleaner cuts.
If you're cutting thick foam (say, a 1/4" sheet,) never use scissors if you can avoid it. They really make a mess.
If you're cutting a fancy or curved design, it's best to use scissors for the thin foam and a pocket knife or jackknife for the thick stuff. It's tricky, but you'll get the hang of it.

  • Ruler
  • Kitchen knife (if possible)
  • Pocket knife or jackknife
  • Pencil (optional)
  • Cutting surface

Step 2: Carving Sharp Edges

This method of carving a blade takes a lot of practice. Even for me, the cut comes out a jagged mess most of the time. Also, the electric kitchen knife shakes the hell out of everything. Be prepared.
  • Foam blade
  • Electric kitchen knife
  • Pencil



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You can use a dremel tool to get a smoother final finish to the weapon. Makes it look much nicer.
Fine sandpaper also helps with that.

I'm not sure about a dremel, if you try it let me know how it goes! Sandpaper, I'm pretty sure, will just snag on the foam and tear up tiny bits so that the foam ends up with a sort of furry texture. However I could most definitely be wrong, and please let me know if I am!