The Best Way to Cut Styrofoam

Styrofoam and other closely related types of craft foam are some of the best and most popular materials in the crafter's repetoire. Inexpensive, light-weight, relatively strong, and shape-able, Styrofoam is a great foundation for both small crafts and larger projects. However, customizing this material can be problematic if you don't know the best tools and methods for cutting and shaping it.

Best Way

• The best way to cut Styrofoam or other similar types of craft foam is with a saw or knife with a serrated edge. Trying to cut this material with straight blades can work in situations where a pair of scissors can do the job, but in general, straight blades will have a tendency to flatten the foam and malform it before cutting, and will not make a clean cut because of the soft, somewhat spongy nature of the foam.

  Serrated blades, on the other hand, tear directly through the foam rather than compressing it.

  There are, of course, a few exceptions: if cutting shapes in thin sheets of foam using a self-healing mat or cutting board, you'll want to use a craft knife instead.

Types of Tools

• There are many types of serrated blade tools that will work well in cutting Styrofoam, and which one you use depends on the project and on the size and shape of the foam you're trying to cut.

  Power saws do excellent work with big projects, whether you're working with large pieces or just a lot of them. Band saws and scroll saws are the ideal choice for this type of work, though you can also use a jigsaw if the foam you have is particularly bulky. Power saws will make clean, even cuts in foam just as they do with wood, but exercise caution and obey safety procedures for working with these tools. Also, bear in mind that the saws will tear through foam much faster than they cut wood, and the foam "sawdust" that is created will stay in the air longer and have more potential to be an irritant, so dust masks are a good idea.

  Hand saws can also be good for cutting Styrofoam, though it's best to avoid saws with blades that flex or wobble since the foam is too soft to make straight, even cuts with these blades; every time they wobble, your cut will change shape or your foam may get extra nicks cut into it.

  Instead, go for a compass saw, coping saw, or hacksaw, depending on the size of your project. These blades will be less likely to veer from their course. You can also use a serrated kitchen knife in a pinch, especially for small craft project. Though smaller and less well-suited for large projects, a steak knife, bread knife, or electric knife will saw through foam almost as easily as a saw.