Shaped cutting foam rubber at home

The pattern of the balloon is easy and simple

In some cases, when you make something either in handicrafts, it may be necessary to make a ball of a certain size and diameter. You can hardly just make one. It requires accuracy. To get the right product, you definitely need a pattern of the ball. Then it will be round and without corners. Of course, the choice of material for the balloon is also important. It has to be non-tensioned.

Of course, there are people who can rely on their eye gauge and by mathematical calculations make a ball-like product. But is it possible to make a proper ball?? Let’s see how you can make it to the exact size.

How to make a pattern of the ball?

The easiest way to make a ball with a diameter of not more than one meter. If the size is larger, there may be some inconvenience.

Usually the ball is made of petals of the same size and shape. They are glued or sewn together along the outlined scythe line. Do not forget to leave seam allowances.

If you make a ball out of foam rubber, you can do not separate petals, but interlocked. That is, you do not need to make each petal separately, and draw the necessary shape at once on the foam. In this case there is no need to leave seam allowances. But this is only suitable for foam rubber.

When making a ball of fabric, each petal is cut out separately and sewn. The seam should be imperceptible, the transition should be smooth.

Getting Started

In order to get the right pattern of the balloon, you must know its diameter, that is, the apparent size.

Next, we must decide how many petals the ball will consist of. A small one can consist of six. The larger the ball and its circumference length, the more petals will be needed.

To know the height of the petal, divide the circumference by two.

To calculate the circumference length of the ball, you need to multiply its diameter by the constant value of π = 3.14.

Accordingly, if the diameter of the ball is thirty centimeters, then the length of the circle is 30 3,14 = 94.2. The height of the petal will be 94.2 / 2 = 47.1 cm.

Next, you can calculate the width of the petal. If we want them to be eight, then the length of the circumference of 94.2 divided by 8, we get 11.775 cm.

Afterword

If for someone all these calculations are complicated, you can look for a special generator of calculations, to get the right pattern of the ball. You just enter the desired diameter and the number of petals, and the program itself generates the size of the future ball (even with seam allowance).

After learning how to sew a balloon from fabric, patterns should be saved. Perhaps they will come in handy more than once.

It is better not to listen to this advice. Even if the cutting of foam rubber will be on the street, you run the risk of inhaling dangerous toxins so that you will ruin your health in a moment. It’s because foam rubber isn’t just plastic. All kinds of toxic impurities are added to polymers to give it a foam structure, which are completely harmless in their normal solidified state and at room temperature, but instantly turn into a most poisonous substance when heated strongly.

Yes, in the manufacture this material is cut by means of red-hot nichrome threads. But people there wear protective clothing and respirators, or even stay in a well ventilated protected operator’s booth. And as you are going to cut foam rubber at home, in the absence of such protective equipment you run the risk of poisoning not only yourself but also your loved ones.

Plus, this method is only suitable for straight cuts. To make a shaped one, you still have to take a knife.

Comment: How to cut foam rubber at home

I thought it would be difficult to cut the foam rubber by myself, at home. But, judging from the description in the article. everything is quite simple. Let’s try it.

Hello all, just recently I faced the problem of how to cut the foam evenly and at home. During all my hobby carpentry, I have never once worked with foam rubber, and understandably, I usually work with wood.

So how to cut foam rubber? And what it takes. The first thing that came to my mind is some expensive machine, which is just not realistic to buy because I once cut foam rubber, but a long time ago, and it did not work out well.

At work, in our shop next door are engaged in upholstered furniture, and then at lunchtime I met a guy on the street who does it. During the conversation I found out that in order to cut the foam rubber they use an ordinary knife, and they don’t have any expensive equipment for that. We got to talking and he told me how to cut foam rubber accurately at home.

To cut the foam rubber you will need the following

• A sharp knife, preferably a box cutter or linoleum cutter
• A highlighter or marker with a fine tip
• Cardboard or something else for the base
• A good ruler

So, how to cut the foam rubber, first using a marker, make a scythe line cut on the foam. If it’s a straight mowing line you’d better use a ruler, if you want the cut to be under a radius you’d better use some sort of mold, template or other device to draw an even radius.

Next, to cut the foam, you will need to prepare the base. As a base, many advise to use plywood or particle board. I would not advise you to do this, as when you cut the foam rubber with the knife, the tip of the knife will blunt against this plywood. So for the base I suggest using cardboard. By the way, I forgot to tell why you need the base, the base is not to spoil the floor or other ground on which you are going to cut foam rubber, but as you have understood for the protection tip of the blade.

And the last point how to cut the foam rubber, is the process of cutting. You need a very sharp knife for that. Your kitchen knife won’t cut it, because its blade is thicker. So I advise to use a penknife or a construction knife like the ones used to cut linoleum. It is very important that the blade and the tip are sharp, otherwise you will not be able to cut the foam evenly.

And then go to work, hold the knife flat on the mowing line, preferably without using the stop, as the stop will press on the foam, thus creating a load in it, and the knife will not cut well. If in doubt of your abilities, it is better to train on another piece of foam rubber, so as not to spoil the workpiece.

And in general, foam rubber is usually cut in order to trim upholstered furniture. So it is perfectly flat can not be done, and you can not 100% cut it all equally. On top of the foam rubber will still be a cloth, which will smooth out all the irregularities and uncertainties of the cut.

Here I am, this article may be useful to those who have thought about how to cut foam rubber at home with his hands. I would be glad to comment, tell me what you think about it, and if you have experience, share it.

It is not uncommon to see advice that foam rubber should be cut with a heated nichrome wire connected to 12 V voltage, as well as with a heated soldering iron.

How to cut a flat thick foam rubber at home?

However it is not recommended to do it at home since foam rubber emits hazardous substances into the air, which even in small doses are highly toxic and affect the respiratory and nervous systems. Risk our health will not, especially since foam rubber is well cut with a regular knife.

Mark out a piece of foam rubber with a marker or marker pen, making small marks. Connect the tags to each other with a ruler (you can use a flat bar).

Place a piece of board, plywood, particle board, or just heavy cardboard under the cut to be made. This will protect the floor from damage when cutting.

It is recommended to cut the foam rubber without a ruler. Move the knife firmly and accurately along the line you have made. Hold the knife vertically at the same time.

If the foam rubber does not cut all the way through, use your fingers to separate the cut and use another cut to cut the foam all the way through.

If the cut is scuffed, it means that the knife blade is blunt. Break off the tip of the blade or replace it with a new one.

Curved cuts are made using exactly the same technique. After marking the pattern then cut the foam rubber along the mowing line, making sure that the knife is vertical without tilting. The quality of the cut will not be perfect, but it is useful if you need to cut a cushion for upholstered furniture, which will then be covered with fabric.

Pre-wetted and thin polyurethane foam is much easier to cut with the scissors.

Laser cut foam rubber.

This method has many advantages over all of the above. The emergence of laser cutting method has immediately improved and optimized the process of material cutting, which allowed to transfer the manufacturing process to a new technological level. The main advantages of cutting foam rubber on a CNC laser are as follows

• Non-contact cutting method. There is no mechanical impact on polyurethane foam, no deformation of the material
• Uniform cutting edge
• Excellent cutting precision due to the thickness of the laser beam of only 0.1 to 0.2 mm
• High cutting speed due to the elasticity (not high density) of foam rubber
• Highly detailed diamond shapes of any complexity
• Minimal waste
• No rejects

There is also a disadvantage of laser cutting foam rubber, it boils down to a limitation in the thickness of the material to be cut. Optimal cutting of foam rubber is within 30 mm. But it is also possible to cut material up to 100 mm thick.

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Cutting foam rubber

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Shaped cutting of foam rubber. why do we need it??

It is often necessary to preserve the perfect appearance of an object in perfect condition. For example, a gift or furnishings when moving. And here’s the question: how to do it? The answer is to use high-quality packaging. And what packaging to choose is another question. Depending on what item needs to be packaged, several materials can be used to make the packaging.

The most common are foam and foam rubber. The foam packaging is usually used for transportation of large fragile items.

In turn, polyurethane foam is most often used in the manufacture of trays. The liner is a lining in the package of souvenir, jewelry and gift items. It is also used in advertising cosmetics, etc. п. In order to make a tray we use the shape cutting of polyurethane foam. It is a technology of cutting foam rubber with a laser, which allows you to cut out of foam rubber products of complex shape.

Laser cut foam rubber is good in that after the cut the material becomes beautiful smooth and even edges. A great advantage of this technology is practically waste-free production. In addition, the material does not deform in the process of cutting.

Laser cut foam rubber can be used not only for the production of trays. For example, in the manufacture of various models, moulages, or decorative items, shape cutting will be a great help. This technology will allow you to cut foam rubber of any complexity. In this case the procedure of cutting will not take much time.

Polyurethane foam is a versatile material that is widely used in many industries. Polyurethane foam is used in the construction industry, in the manufacture of insulation, in furniture production, in the clothing industry, etc. д. The popularity of this material due to the low price, ease of use, low weight and unique characteristics.

If you need the service figured cuts foam rubber, please contact us.

Cutting instructions

If you follow the instructions, your polyurethane foam will cut perfectly. So, here we go:

• Since we decided to cut the foam on the mat, not on linoleum or parquet, we put it first. Plywood first, then a sheet of cardboard.
• Lay on top of the layer of foam rubber that we want to cut. Make sure that the line of the future cut falls on the lining.
• We take the ruler and according to our measurements we draw a line, along which the future cut will be made.
• Remove the ruler. If we will cut along the ruler while pressing it, the cut will be straight, but the edge will be as depressed as it was with the scissors. If you decide to cut with the ruler, do not put any pressure on it.
• We take the knife, adjust the blade to the desired length and make a small cut over one side. Many people wonder how to cut thick foam rubber so that even at the edge, in the place of the original cut, it is flat. There is really no difference in the thickness of the foam itself. The main thing after the first cut is to insert the knife into the original cutting line and make the first full cut, slightly gripping both edges of the cut foam rubber on both sides of the knife with your free hand. Then the cut will be perfect.
• In many articles advisors recommend to keep the knife vertically. Copy each other, without understanding it. Don’t listen to idiotic advice. The knife, on the contrary, should be tilted toward you. It is the plane of the knife blade should always be in a vertical position in relation to the ground. You can’t bend it to the right or left, or the edge of the cut will be trapezoidal.
• It is certain that with the first cut the foam rubber will not cut through to the end. Patience. It is nothing to worry about. Spread the edges of the cut, insert the knife and make another even cut. Eventually the tip of the blade will rattle on the cardboard and the task is done.

Useful advice on how to cut foam rubber to have a perfect edge. If you feel that the knife began to make a kind of hooks during the wire, it means that in some place the blade blunted and not cutting through, begins to tear foam rubber, forming a strip of foam burrs. In this case the blade should be immediately replaced with a new one. It is best to do it without waiting for it to happen. Make five or six wires, change the blade. They can be used again later for any other purpose, but they will not be good for cutting foam rubber. A simple cut of foam rubber with a knife is illustrated in this video.