Cutting Kaizen Foam

[John Hollaway]

Has anybody here ever tried cutting Kaizen Foam with a router? Results? Thanks.

[Jim Becker]

I have not used the product, but due to the layered nature of the product, I'd be concerned about it being "caught" by the tooling and "chunked" out. There is also the issue of heat from the spinning tooling, even if it's at the slowest speed possible for the given router. Kaizen was designed to be cut manually with ease so that's likely how I'd use the product.

[James Jayko]

I'm tempted to try some electric foam cutters...

https://hotwirefoamfactory.com/pro-tools-w-out-power/

[Anthony Whitesell]

I did not try to contour the foam (rounded edges). I just used a new small break off utility knife to just only the layers I didn't need. The break off utility knives were the skinniest blades I could find so it could make the tightest corners.

[John Stankus]

Not sure handheld, but there are videos of CNC routers being used to cut foam
https://www.youtube.com/watch?v=j3LGMc3H9mI

The right bits will make a difference
Amana 46272
Datron 0068055K (6mm shaft)

[Brian Gumpper]

Amana makes some foam cutting bits that should work with that material. I've sold some to boat manufacturers that cut thick foam for boat hulls, not sure what material they are using though.