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Thread: How to make beautiful, smooth cut of curved shapes made of EVA foam?

  1. How to make beautiful, smooth cut of curved shapes made of EVA foam?

    Hello, I want to make shapes using EVA foam of 10mm thick. I used sharp cutter but it was difficult to make absolutely vertical cut of curved shapes. I tried laser cutter but it leaves dark burned mark. I used sand paper (don't know why it is gray color) of 500 grade to remove the dark burned marks. However, the foam became grayish. I tried to use water to remove the grayish surface without success. Bright color does not look bright anymore. Any suggestion on how to make beautiful, smooth cut of curved shapes made of EVA foam of 10mm thick while maintaining bright color?

  2. #2

    Re: How to make beautiful, smooth cut of curved shapes made of EVA foam?

    The internet suggests an X-acto® Foam Board Cutter and lots of practice.
    If you have very intricate parts, you can likely also use a "hotwire" cutter, and you can even get CNC machines that have those kinds of cutters.
    Last edited by jwatte; 12-11-2015 at 05:27 PM.

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    Re: How to make beautiful, smooth cut of curved shapes made of EVA foam?

    Also easy to build your own hot wire cutter with some cheap nichrome wire, some wood scraps, a few screws, an old power supply, and maybe a spring to keep the wire well tensioned. Nichrome wire does not solder well, so crimp connectors and/or wrapping around a bolt and squishing it between nuts tend to be preferred means of joining it to other objects.
    Please pardon the pedantry... and the profanity... and the convoluted speech pattern...
    "You have failed me, Brain!"
    bleh

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