How to Cut Foam

Polyurethane foam is a versatile material often used in a variety of applications, including upholstery cushioning, acoustic treatment, mattress making and much more. It is a popular choice for both professionals (such as upholsterers) and DIY enthusiasts. If you’re wondering how foam is cut or how to cut foam at home, allow us to explain.

Cutting Foam at Home

Before you take the kitchen scissors to a new piece of foam, there are a few methods you can consider to achieve a better shape and finish.

To cut your foam more accurately, you’ll need to determine the size and shape of the finished piece you need. You can do this by working around a template or by taking accurate measurements and marking the foam for guidance.

When you’re ready to start cutting the foam you’ll need to choose an appropriate tool. One of the most accessible tools you can use to cut foam at home is an electric carving knife. These do quite a good job of cleanly cutting through the material. If you don’t have one of these to hand, you could also try using a long, sharp serrated knife. As always, you should be especially careful when handling sharp tools.

Foams that can be cut at home or work using methods such as this include polyurethane foams (including acoustic foam, packaging, memory foam and various types of high-density upholstery foam) and closed cell foams (including Plastazote). If possible, it’s best to test your cutting method on a smaller scrap piece of foam first to ascertain the effectiveness of your tools.

Do not use a hot wire foam cutting tool to cut polyurethane foam, as these are intended for cutting materials such as Styrofoam. They work by heating a thin wire to a high temperature to melt through the material. Polyurethane foams are manufactured using plastic polymers and should not be melted.

How Foam is Cut by Professional Foam Converters?

If you’re looking for professionally cut foam with a superior finish, we can help! GB Foam has been cutting foam to size and shape since 1976 and you’ll be glad to know that we have more than an electric carving knife at our disposal to create your high-quality foam products.

Our factory is equipped with a wide array of advanced machinery pieces designed to professionally cut foam in a variety of ways. Foam converters utilise these machines to create many foam products we use daily, including sofa cushions, memory foam mattresses, acoustic tiles, packaging foam and so much more.

Foam Cutting Machines

Here are just a few examples of foam cutting machines that can be used by foam converters to cut and shape foam.

CNC Routers

CNC (Computer Numerical Control) machines such as CNC routers can cut a variety of materials including foam. The cutting tools are guided on an X, Y, Z axis, with the use of a computer that follows specific instructions outlined in a dedicated file. The machines are known for quickly and accurately producing high-quality foam products with the ability to replicate the process as required.

Band Knife Cutters

Band knife cutting machines are manually operated tools designed to cleanly cut through foam. A piece of foam is laid out onto the flat surface of the machine and a skilled foam cutter guides the material through a long, sharp, vertical blade. This is a versatile machine that, when operated correctly, can produce a variety of foam shapes.

CNC Water Jets

Water expelled at an extremely high pressure can cut through a surprising number of materials including foam. CNC water jet cutting is generally used to produce foam products with more intricate details.

Profiling Machines

Whilst not specifically a tool used for cutting foam, profiling machines are used to create indentation patterns in foam. This is achieved by passing a piece of foam through a heavy, shaped roller. It can be used to create foam sheets with various types of profiling.

Horizontal Cutting Machines

This type of machine is used to create foam sheets of varying thicknesses. A block of foam is continuously passed through a sharp, horizontal blade which lowers as the foam is cut down.

Buy Custom Cut Foam Online

If you’re in need of a custom foam product, you can always use our foam cut to size service. By using a professional foam converter, you’ll be able to buy foam products with a professional finish.

Whilst foam can be cut at home using the methods discussed, it’s best to use a professional company.

Head over to our foam cut size page to begin your order. All it takes is 5 simple steps. If you have any questions about our products or services, you can always contact us directly to find out more. Visit our contact page or call us on 01494 441177.