Cutting Flexiable Foam

[rod1949]

I recently brought a Walkera Tali H500 Hexacopter Drone, the makers do not have custom made foam lined case for them so I need to make one.

My question is how does one cut or sculpture the foam to suit the shape? Ideally, it would be great to sculpture the foam from one thick slab but in reality cutting in straight sided layered sections is what I'll probably do. Any suggestions are appreciated. Thanks in advance

Rod

[Cliff Rogers]

Hot wire cutter.

http://www.ebay.com.au/sch/i.html/_W0QQ_sopZ12?_nkw=hot-wire%20foam%20cutter&_fromfsb=0&_trksid=m270.l1313

[Cliff Rogers]

I've also had some luck using a bread knife.

[david.elliott]

Get a cheapy from the dept store for $20 or so and do your best...
We've just lined a studio with acoustic foam, makes it scary easy.

[doug3030]

My question is how does one cut or sculpture the foam to suit the shape? Ideally, it would be great to sculpture the foam from one thick slab but in reality cutting in straight sided layered sections is what I'll probably do. Any suggestions are appreciated. Thanks in advance

Years ago I bought some foam and they cut it with a saw that looked like jigsaw but with a flat plate below the blade that the foam ran on, similar to Cliff's hot wire cutter but with a reciprocating blade.

This makes me think why not use your bandsaw, if you have one?

Cheers

Doug :2tsup:

[underfoot]

My question is how does one cut or sculpture the foam to suit the shape? Rod
..it's not often I feel like I can speak with such authority..
.....however, I have just helped my son build a travel case for his phantom quadcopter (and related gopro paraphenalia)
..we used a soft foam (that yellow stuff used in cheap mattresses)..
..we used a profile gauge to get the pattern, marked it out on the foam and cut it out with a bandsaw.
(thought that the foam might pull down the throat of the saw but it didn't)

[Old-Biker-UK]

Spent many an hour when working in a museum, cutting closed cell foam drawer inserts for small antiquities.
Cut-outs made using surgical scalpel and layers bonded using low-temp hot-melt glue gun.
Sculpting can be done on the layers, again with the scalpel.
We mostly used these blades http://www.amazon.co.uk/s/?ie=UTF8&keywords=scalpel+blades+10a&tag=googhydr-21&index=aps&hvadid=23274898849&hvpos=1t1&hvexid=&hvnetw=g&hvrand=4084620039205879667&hvpone=&hvptwo=&hvqmt=b&hvdev=c&ref=pd_sl_9h6kvlq499_b

Mark

[crowie]

My wife is an Occupational Therapist and often uses an electric knife to shape high density foam for clients....

We use a Bosch Foam Cutter at the local Boys & Clubs Club to cut the gymnastic mats in....

I have made a "hot wire" foam cutter for shaping Styrofoam for my model railway layout....[I have plans if you'd like a copy]....

Cheers, crowie

[Tonyz]

Second hand stores......... electric bread knife mine cost $3. works brilliently