Cutting EVA foam

[MichaelBikel]

I'm cutting EVA foam with a compass style circle cutter but the foam is too thick to cut through, and the tool doesn't accept bigger blades. In order to get all the way through I have to flip the workpiece over and cut from the backside too, of course this looks pretty sloppy. Any ideas? Cheap is best!

 

[frozen-stitches]

I use Kai shears if it’s a thin foam, over half an inch I use a foam saw. I think you can also use a hot wire on the Eva foam.

 

[WoodsTruck]

If you use a hot wire, use some test pieces to determine edge shrinkage and travel speed. If you go too slow, or slow down, you will create a large heat out area.

2" blue foam insulation cut into 4" squares for a project. Cutting wire setup with a rip fence.

 

[Milton Shaw]

Electric kitchen knives work fairly good on most foam types. You might give it a try, and it doesn't mess up the knife so that it can't be used for the turkey in a month or so..

 

[MichaelBikel]

Thanks guys, I've seen the hot wire method used on custom styrofoam airplanes before. I was hoping to not have to make a tool to cut them myself, especially one that takes up room. At the moment I think the hot wire would be the easiest and provide the cleanest end product.

This is the tool I was using before which would have been great but the foam is about 1" thick and the blades it accepts are very small

https://www.amazon.com/dp/B000BK7NWC/?tag=atomicindus08-20

 

[Guster]

I frequently made EVA plugs using a custom wad punch made from a piece of thinwall tube ground sharp on the inside or the outside depending on the side you want clean and straight in the cut. The 6" ones are done in a press between MDF plattens rather than with a hammer.

EVA also often cuts better with an abrasive cutter than a saw or knife style cutter. It is easy to clean up edges with a drum sander or similar tool if you cut smaller and sand to dimension.

 

[rlitman]

...
This is the tool I was using before which would have been great but the foam is about 1" thick and the blades it accepts are very small

https://www.amazon.com/dp/B000BK7NWC/?tag=atomicindus08-20

So get a longer blade for it. Can you fit an x-acto blade in there? Or maybe the blade from a snap-off utility knife?

 

[bradpac]

snap-off utility knife blade is what came to mind for me too. Not sure how tough it would be trying to run it through 1" of foam though.

 

[Keyblazer]

Bandsaw?

 

[metalmad]

Holesaw?
What size are you cutting?