Instructions / Assembly

2 | P a g e
Usage and Fabricaon Guidelines
MACHINING Foam can be used in the fabricaon of variety of arfacts using common tools and
machinery as recommended in this secon.
General Rules When machining Foam with high-speed equipment, using carbide pped tools is
recommended. Lower speeds usually work beer and always use sharp tools to ens ure
smooth edges.
Cung Sheets of Foam up to 3 mm thick can be cut with a ulity knife. Table and band saws,
including routers, can be used to cut thicker gauges. Power shears or guillones are not
recommended. They can cause edges to be crushed.
Stamping and Stamping and die cung are cost-effecve methods for the efficient
Die Cung manufacturing of large quanes 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 instrucons on die cung, please call our toll
free number on the back of this manual.
Note:
Avoid making shapes or cung 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 illustraon 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 cung speed of 8,000 to 12,000 feet per minute and a feed speed of
70 to 90 feet per minute. (see illustraon 2)
When using band saws, high speed steel blades used for cung wood or plasc are
commended with 4 to 8 teeth per inch at a cung speed of 3,000 to 5,000 feet per minute
and a maximum feed speed of 40 feet per minute.
Illustraon 2:
Rake Angle: 0° to 15°
Clearance Angle: 10° to 20°
Tooth Pitch: .080” to .400”
Cutting Speed: 8k to 12k ft/min
Illustraon 1:
Recommended Not Recommended