Instructions / Assembly
Table Of Contents
2 | P a g e
Usage and Fabricaon Guidelines
MACHINING Foam can be used in the fabricaon of variety of arfacts using common tools and
machinery as recommended in this secon.
General Rules When machining Foam with high-speed equipment, using carbide pped tools is
recommended. Lower speeds usually work beer and always use sharp tools to ens ure
smooth edges.
Cung Sheets of Foam up to 3 mm thick can be cut with a ulity knife. Table and band saws,
including routers, can be used to cut thicker gauges. Power shears or guillones are not
recommended. They can cause edges to be crushed.
Stamping and Stamping and die cung are cost-effecve methods for the efficient
Die Cung manufacturing of large quanes of pieces where edges require no routed finish. For
best results, it is very important to cut the material AT THE RIGHT TEMPERATU RE (70-
100 degrees F). As a rule the lower the sheet temperature, the less consistent the
process and the edge finish. For complete instrucons on die cung, please call our toll
free number on the back of this manual.
Note:
Avoid making shapes or cung 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 illustraon I)
Sawing For best results, use carbide pped 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 cung speed of 8,000 to 12,000 feet per minute and a feed speed of
70 to 90 feet per minute. (see illustraon 2)
When using band saws, high speed steel blades used for cung wood or plasc are
commended with 4 to 8 teeth per inch at a cung speed of 3,000 to 5,000 feet per minute
and a maximum feed speed of 40 feet per minute.
Illustraon 2:
Rake Angle: 0° to 15°
Clearance Angle: 10° to 20°
Tooth Pitch: .080” to .400”
Cutting Speed: 8k to 12k ft/min
Illustraon 1:
Recommended Not Recommended