Tools

The tools which can be used to carve the foam piece depend on the amount of material you want to remove.

Hot Wire Board: A wire is heated up and it is used for high volume removal or refining details. The hotter the tool the faster it will melt the foam; however it will create more fumes. The perfect temperature for the hot wire is one where the tool moves through the foam without producing drag or smoke.

This should be used with care, ventilation and respiration is recommended; the heated components can burn skin and fumes created by the melting foam though typically not toxic can smell offensive.

Carving knife or cutter. This tool with a really sharp edge will help to form some of the parts of the sculpture.

Filing and Rasping Tools – Many abrasive tools can be used to sculpt foam. Choose a fine or coarse abrasive depending on the volume of material you wish to remove. Coarse tools (rasps) can be used for high volume removal and fine tools (files) can be used for final shaping.

Another tool which we use is a nail file, which is convenient for small details

Sand papers – Sandpaper should be used for refining the final shape

Process

Look and touch your EPS piece. Imagine what can be carved out of this piece.

Drawing: Draw on a piece of paper your design. Imagine the several views. At least two. From the side or lateral view and the front view.

Cut out the paper with the side view and glue it on the side of your foam piece.

Go to the hot wire board and cut out the shape. The wire will cut out the EPS but not the paper. Do not force the hot wire through the foam.

Place the foam piece on the board and apply light steady pressure to carve the foam by melting it. The hot wire “cuts” the foam by melting it and should be allowed to move at their own pace. Excessive force can break the tool.

Sketch your design with a permanent marker on your foam before carving to get a general idea of the form

Use a carving knife to better define your shape. It needed a really sharp edge and just a light brushing with the cutter to form some of these parts.

Use rasps and file to carve out and remove the pieces of foam. Don’t be too aggressive. What you remove can’t be replaced. So, work slowly until you get to know the use of the filing tools.

Round out the shape using nail files for small details. and sandpaper to smooth the foam and refine the final shape

Cleaning and Safety

The foam beads, when carving, scraping, and sanding, gets everywhere. Beads are highly static and will stick to you and everything else. You can wear an apron. And use a bowl or bag to put the pieces which are being removed. We also suggest wearing a dust mask when carving. Safety goggles also to keep dust out of your eyes.

The hot wire board should be used with care. Good ventilation and respiration is recommended; the heated components can burn skin and fumes created by the melting foam though typically not toxic can smell offensive.

Be careful with the sharp edges of the knives and cutters.

Before you go, don’t leave everything in a mess. Sweep the floor, please