Cutting Sponge?

topic posted Sun, August 30, 2009 - 1:52 PM by  Azeeza
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I bought a big thick piece of sponge from Joann Fabric years ago and I never learned how to cut it properly. All the edges were ripply when I did cut it.

Can anyone tell me how to cut sponge to fit as a seat cushion or anything to make a nice smooth edge? An electric knife didn't do it.

Thanks,

Azeeza

PS Will try the snake in the drain tonight when I can find the snake :-)
posted by:
Azeeza
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  • Re: Cutting Sponge?

    Sun, August 30, 2009 - 5:04 PM
    Use an exacto blade. If the foam is thicker than your blade, pull the cut open when making the second cut. Don't saw at it, just make a clean slick.
  • Re: Cutting Sponge?

    Mon, August 31, 2009 - 6:31 AM
    electric knife, hot wire. compress the foam with blocks and use any blade.
    Whatever blade you use: It's gotta be sharp.
    • Re: Cutting Sponge?

      Mon, August 31, 2009 - 7:27 AM
      The trick is to use a long, sharp blade. The use long smooth strokes, pulling the foam apart as you go along. I f it's like 4" thick it will probably take a couple of passes. hold the cut open when making the follow up cuts.
      • Re: Cutting Sponge?

        Tue, November 3, 2009 - 9:48 AM
        I have had success using a wicked sharp breadknife (the kind with scalloped serrations not jagged), compressing the sponge/foam and using long smooth pulling (not back and forth) strokes. Its best to try to get through it in as few slices as possible to make it clean.
  • Re: Cutting Sponge?

    Mon, August 31, 2009 - 8:57 AM
    Thanks for all the suggestions. I like the hot wire idea, but my husband and I used a bread knife before. I looked at the stroke marks hubby left from the last time we used the foam and it wasn't as bad as I remembered it being. The sponge is pretty thick and heavy. I remember paying a lot of money for it. I'm always working on some sort of project it seems.

    Azeeza

    PS My next post is a jig recommendation post :-)
    • Re: Cutting Sponge?

      Thu, November 5, 2009 - 10:23 AM
      Not sure if this is the solution you were looking for, but I've carved foam (several different types, including both open cell and closed-cell) with an electric turkey carving knife. It did leave riffles from the serrated knife edge, but they pretty much became part of the design. It works well because you replace the pressure of you pushing on the foam as you cut (which deforms the foam) with the sawing motion of the knife. Then you manage the pressure as you go.

      I made some sea-horses- about 3' tall and 12" deep that we put on sticks and wired up with EL wire and mounted on the backs of our bikes one year for night-time friend finding on the playa at Burning Man. It was kind of like carving those wooden horses that you could get with hobby kits back in the day when I was a kid (aghh!).

      have fun!
      Chris
  • Re: Cutting Sponge?

    Mon, August 31, 2009 - 10:27 AM
    You're talking about foam, rather than sponge, right? I've redone quite a few chairs, I always use a utility knife, the kind that's bright orange plastic and you can snap off the blade when you need a sharper edge. With those you can extend the blade a good 3 inches and it works great for cutting foam to a fairly smooth edge.
    • Re: Cutting Sponge?

      Mon, August 31, 2009 - 9:27 PM
      For cutting slab foam for furniture or bed use>>
      I use a well honed 25cm blade Japanese sushi knife. ...a small little razor knife won't do it. First mark the line of the cut with a Sharpie. then compress the foam with a long preferably metal straightedge on the marked line. Then draw the knife along the aligned straightedge with a deliberate smooth consious pressure watching at all times to see that your blade stays precisely vertical. If necessary go back and shave off some areas of the resulting cut that may appear higher until it looks about right.

      For cutting sponge, natural sponge, as used in the bath..>>
      first soak it, then squeeze out, then freeze it, then take it out of the freezer and saw it to shape while it's still hard.
  • Re: Cutting Sponge?

    Wed, September 2, 2009 - 7:16 AM
    I like the idea of an exacto knife. I'll have to try it next time. It's foam/sponge? I bought at Joann's a few years back and it's blue. I imagine it's used for covering with decorator's fabric to replace worn out cushions. It has tiny holes in it, so I figure it was sponge and not foam, it is synthetic and not natural foam/sponge.

    The project is done and it's kind of a success, so on to the next.

    Thanks everyone,

    Azeeza
  • T
    T
    offline 0

    Re: Cutting Sponge?

    Tue, November 3, 2009 - 7:40 AM
    Hello Azeeza. If you have access to a band saw then this machine is the best most accurate and easiest method to cut almost any density of foam material. In the past I have tried several methods and then wandered into an upholstery shop where a band saw was used. I am fortunate enough to have one in my shop and can cut paper thin pieces with it..
    • Re: Cutting Sponge?

      Tue, November 3, 2009 - 12:19 PM
      What blade pitch - what speed?

      I have images of the foam being dragged down into the guides below the table.
      • Re: Cutting Sponge?

        Tue, November 3, 2009 - 5:24 PM
        I can totally envision a narrow fine-toothed band set to quick, slicing easily through a firm foam slab without alot of fuss.

        But if you're worried about the foam being so tonelessly flabby that it gets dragged down into the sawtable slot and causing a big mess, then one could emplace a 1/8" thick section of wall paneling under the work to hold it firm during the cut. The cut wouould go through both the foam slab and the sacrificial thin wood paneling.

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