How do I cut sheets of styrophome and get a nice clean edge?

Answer 1

I just recently answered this same Q in detail. I see valid answers here so far.

The issue is in part, the thickness you wish to CUT, and the intended use after the fact.

A HOT WIRE, is not strictly taking a coat hanger and heating it up, but there are specific TOOLS designed for the purpose. The one I use looks a bit like a band saw with a decent sized TABLE and rather than a saw blade it has an electrified wire. Certainly you can use it with a straight edge or for scroll work.

Another tool I use, primarily for theatrical work is a HOT KNIFE, which is sold with various BLADES, and it can be used even to cut foam to look like molding.

Another issue is the type of foam you wish to cut. The large cell usually white, often used for packing, type, is more difficult to cut than any that has a more dense cell structure, IE: Construction grade insulating foam sheets.

Certainly a utility knife with a sharp blade will do decent straight cuts, but the normal utility knife blade only extends about 5/8 inch from the tool.

I also have used a hacksaw blade which minimizes rough edges.

Unless you have the ability to craft your own HOT WIRE tool, you might check places like Ebay. Either tool I mentioned, that I use are not strictly bargain items, and unless you plan to cut a lot of Styro, and depending on it's end purpose you should probably try the knife or hacksae blade.

Steven Wolf

Answer 2

The best way is to use an exacto-knife that you can pick up in any hardware store. Or you can use a stain glass cutting method: make an incision in the styrophome all the way down the length of the sheet, the use your hands and break the piece off. You can trim it afterward.
I recommend the exacto-knife if it's a small bit of styrophome (width wise), and the other method if it's a larger piece.

Answer 3

You can heat up an old butter knife on your gas stove or use some other flame source. This will melt the foam with a nice clean edge and will prevent it from flaking off the little balls.

Answer 4

We just cut sheets insulating foam and used the table saw. It made nice clean edges. This was for large sheets.

Answer 5

i have done alot of work with styrofoam making sets for plays. the best way to do it is with a heat knife which is specially made for cutting foam. If you don't have profesional tools then use a table saw and you get something pretty close to a factory edge on your foam

Answer 6

A hot knife set. This set has different size blade cutters for all jobs.

There is also a special cutter used for foamboard. I cant think of the name but it cuts slowly and with an extremely fine saw.

Answer 7

Use a stanley knife and a straight edged impliment as a cutting guide.

Answer 8

Retractable utility knife, use a T-Square or a long ruler as an edge.

Answer 9

On one of the decorating shows, the woman cut her Styrofoam with an electric Knife. and it looked good to me.Who would have thought.

Answer 10

Professionally it is usually done with a hot wire.