How to Cut Polyethylene Foam Sheets

Polyethylene foam sheets, which are more commonly called PE foam, are used mostly in product packaging as cushioning. Its lightweight and semi-waterproof qualities make it a popular choice for floatation devices and swimming pool toys. In thinner layers, the foam is wrapped around furniture items to prevent them from getting scratched during shipping.

Things You'll Need

• Safety glasses
• Marker
• Table clamp
• 1/16-inch diamond or carbide saw blade
• Table saw

Instructions

1. Put on safety glasses to protect your eyes from small pieces of flying foam. You do not need to wear a dust mask, since polyethylene foam does not create dust when cut.

2. Lay the foam sheet on a flat work surface. Draw a line on it where you want to cut.

3. Secure the sheet to the work surface with table clamps. Make sure that the cut line hangs off of the table by at least 1 inch to allow you to cut the foam without cutting the work surface.

4. Install a diamond tip or carbide saw blade into a handheld electric saw or table saw. The best blade to use is a 1/16-inch with 1.25 teeth per inch of blade.

5. Turn the saw on and push it slowly across the marked line on the foam until you have cut all the way through it.

References

• 8Linx: Polyethylene Foam
• Yemm & Hart: Origins, Fabrication and Installation