How to Cut Styrofoam

If you cut Styrofoam incorrectly, the plastic foam may crumble or break in the wrong spots. Try these cutting methods the next time you work with a piece of Styrofoam.

Difficulty: Easy

Instructions

Things You'll Need:

• Countertops
• Small Or Large Hot-wire Styrofoam Cutters
• Styrofoam
• Candles
• Plastic Foam
• Tables
• Butter Knives
• Serrated Knives
• Credit Cards And Loans
• Saws
• Craft Knife
• Saws
• Candles
• Tables

1. Use a waxed serrated knife, saw, floral knife or other craft knife to cut Styrofoam sheets and shapes. Draw the knife's blade over a plain candle to wax it thoroughly and then cut Styrofoam with long, sawlike motions.

2. Score a Styrofoam sheet along the desired cutting line. Use a butter knife, credit card or any thin, sharp-edged item to make cuts at intervals along the cutting line. Penetrate the entire thickness of the foam. Gently break the sheet over a countertop or table and use a knife to cut off any excess foam.

3. Invest in a hot-wire Styrofoam cutter if you work with Styrofoam on a regular basis. These are devices that use a heated wire to slice through the Styrofoam. Detailed shapes can be cut easily with these tools.

4. Cut Styrofoam for small craft projects with an inexpensive ($50) cutter. This type is ideal for home crafting and is available at both online and local craft stores.

5. Consider a larger, more durable Styrofoam cutter if you do a lot of projects that involve large amounts of Styrofoam. These are more expensive than the smaller, craft model but are well worth the price if you use it on a regular basis. This tool starts at approximately $200.

Tips & Warnings

• Use a small piece of Styrofoam to smooth the rough edges on another piece of Styrofoam. Rub area until rough edges disappear.

[laptopleon]

on 1/16/2009 It's easy - and cheap - to make your own professional styrofoam cutter. Here's an example: http://www.vatsaas.org/rtv/construction/HotWireCutter.aspx but you can also see the links at http://en.wikipedia.org/wiki/Hot-wire_foam_cutter#Handheld

[colonele]

on 2/27/2008 I also used a soldering gun, but I made my own tip out of 12 gauge copper wire. Formed the wire into a tip, mounded the mounting nuts, bent the ends to go into the gun, then flatted the copper with a hammer. Works like a champ, no fumes, no mess. The wire has a tendency to bend a little, so you have to turn the gun around to bend them back. Other than that, works great.

[colonele]

on 2/27/2008 Quick and Easy, Use a Weller Soldering Gun. Take a piece of 12 gauge bare copper wire, form it into a tip, long enough to go through the styrofoam. Mount the attaching nuts if equipped, bend the ends to fit in the gun, then take a hammer and flatten the copper wire a little. Works like a champ, no smoke, no fumes. You do have to alternate how you hold the gun as the wires do tend to bend if you put to much pressure on them. Just turn the gun around to bend them back.

[deeandra]

on 11/11/2007 The electric knife worked great, thanks. Nice to get some use out it other than carving a turkey one time a year.

[tedyost1970]

on 3/6/2007 I need to cut 1/4" wide by 3/8" to 1/2" deep grooves into a 4' x 8' sheet of styrofoam, or more accurately, blueboard/pinkboard.

Am thinking some sort of jig would be good to do multiple grooves at once, and to keep them parallel.

Horizontal spacing would be 1 groove every 3/4" to 1 groove per 1".

Any ideas on how to do this efficiently, accurately, and low cost?

thanks in advance!
tedyost1970 (at) hotmail-dot-com