Things You'll Need:
- Expanded polystyrene foam or extruded polystyrene foam
- Foam carving hotwire tools
- Face mask
- Protective eye gear
- Black marker
- Overhead projector
- Paper
- Printer
- Water-based acrylic paints
- Paintbrushes
- Water
- Towels or paper towels
- Interior/exterior foam coat sealant
- Foam glue
- Toothpicks
- Foam finishing coating (epoxy or gypsum)
- 80 to 180 grit sandpaper
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Step 1
Transfer your sculpture pattern to the foam with a black marker by drawing freehand or using an overhead projector to project an image to trace. For smaller projects, print a pattern out on a printer, pin the pattern to the foam, and trace over the lines in the pattern leaving an indention. If you are carving a three-dimensional sculpture, remember to trace all sides.
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Step 2
Use a foam carving tool, such as a sculpting tool, freehand router or hot knife, to create the shape of the sculpture following your pattern. Use small movements to shave away foam, creating the initial shape
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Step 3
Use sandpaper to lightly smooth the surface of the foam sculpture.
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Step 4
Use a foam engraving tool to create detail in the sculpture. Hold the engraving tool as if you were drawing with a pencil. Generally, only the tip of the tool heats up.
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Step 5
Use foam glue to glue any separate pieces of foam to the main sculpture. For example, you may wish to glue a small, foam nose to a larger foam face. Insert toothpicks through the small foam pieces to hold in place until the foam glue dries.
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Step 6
Apply a sealant to create a hard surface. Allow the sealant to dry for 24 hours.
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Step 7
Apply a base color (such as white or yellow) of water-based acrylic paint to the entire sculpture. Allow the paint to dry for 24 hours.
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Step 8
Paint the sculpture with water-based acrylic paints. Allow the paint to dry for 24 hours.
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Step 9
Apply a foam finishing coat by painting or spraying to achieve the finished product. Allow the finishing coat to dry for 24 hours.
