How to Cut Foam Rubber
There are several different ways to cut foam rubber. The method you choose will depend on the thickness of the foam rubber and the amount you need to cut.
For small jobs, a simple X-Acto knife may be sufficient. For somewhat larger jobs, an electric carving knife is a good choice. For very large jobs, you may wish to use a band saw.
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Things You'll Need
- Foam rubber Sharpie Straight-edge X-acto knife Electric cutting knife Band saw
Instructions
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How to Cut Foam Rubber
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Using a a fine-tip felt marking pen, sketch out the design you wish to cut directly on the foam rubber. Use a straight-edge to make straight lines.
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When cutting foam rubber less than 1 inch thick, compress the foam with your fingers and make a succession of small, shallow cuts with your X-acto. As one area is cut, move your fingers and compress the next. Continue until the entire pattern has been cut.
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Thicker pieces of foam rubber, up to approximately 3 to 4 inches thick, may be cut with an electric carving knife. Put the thinnest and sharpest blade you have on the knife. Start the knife before touching it to the foam rubber to prevent ripping. Hang the areas to be cut over your cutting table and slowly run the knife around the traced design.
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To cut even thicker pieces of foam rubber, use a band saw. Start the band saw and slowly push the foam rubber into the blade, following the line of the pattern you have drawn.
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Tips & Warnings
If necessary, you can compress the foam rubber with small pieces of thin board and clamps before running it through the band saw. This can be a good idea if you are cutting more than 6 inches of foam. The more dense the foam rubber, the easier it is to cut. Very light and fluffy foam rubber can be very difficult to cut and almost always requires the use of an X-Acto knife.
Use caution when using any electrical cutting tool. Wear eye protection when using a band saw.
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Comments
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fraydo7
Sep 15, 2010
I would imagine that using a bandsaw for say typical soft foam used for bedding would be extremely dangerous. If shoved in just a little too quickly, it could snag the blade, with unexpected results. It might even cause the blade it to break! I have not tried it though. -
fraydo7
Sep 15, 2010
A long serrated edge kitchen knife, preferably stainless steel, can also be used to cut foam rubber. The blade should be longer than the depth of the foam. Use a Sharpee marker and a straight edge to draw your line. Then using a metal straight edge to guide your blade, drag the knife lightly, but quickly, allowing the rounded serrated tip of the knife to score the surface. Make progressive, gradual, light, cuts. A 20 degree angle of the knife edge to the surface works well for the first cuts, then 45 degrees for the rest. Your task will be to keep the side of the knife at 90 degrees to the surface, so you will have a good square cut. Have something hard that won't damage the knife underneath, like a board. You'll have to press a little harder against the board to score the bottom 'skin' of the foam.
