Instructions / Assembly

2 | P a g e
Usage and Fabrication Guidelines
MACHINING Foam can be used in the fabrication of variety of artifacts using common
tools and machinery as recommended in this section.
General Rules When machining Foam with high-speed equipment, using carbide
tipped tools is recommended. Lower speeds usually work better and
always use sharp tools to ensure smooth edges.
Cutting Sheets of Foam up to 3 mm thick can be cut with a utility knife. Table
and band saws, including routers, can be used to cut thicker gauges.
Power shears or guillotines are not recommended. They can cause
edges to be crushed.
Stamping and Stamping and die cutting are cost-effective methods for the efficient
Die Cutting manufacturing of large quantities of pieces where edges require no
routed finish. For best results, it is very important to cut the material AT
THE RIGHT TEMPERATURE (70-100 degrees F). As a rule the lower the
sheet temperature, the less consistent the process and the edge finish.
For complete instructions on die cutting, please call our toll free number
on the back of this manual.
Note:
Avoid making shapes or cutting holes that require sharp corners because
it creates a weak area that can be broken. Easing off these angles with a
radius is recommended. (see illustration I)
Sawing For best results, use carbide tipped circular saw blades with a rake angle
of 0 degrees to 15 degrees and a clearance angle of 10 degrees to 20
degrees with a tooth pitch of .080” to .400”. Saw at a cutting speed of
8,000 to 12,000 feet per minute and a feed speed of 70 to 90 feet per
minute. (see illustration 2)
When using band saws, high speed steel blades used for cutting wood or
plastic are commended with 4 to 8 teeth per inch at a cutting speed of
3,000 to 5,000 feet per minute and a maximum feed speed of 40 feet per
minute.