It is possible to make pillows or costume heads using shaped foam.If you follow these instructions, you will be able to mold foam into any shape you want.Proper steps, tools, and imagination are needed to turn ordinary foam into unique shapes.
Step 1: You can choose a shape to mold.
Pick a shape that is appropriate for your skill level in carving and melting foam.If you're new to foam, make something simple like the heart depicted in the image above.If you are confident in your ability to mold, try a sphere or pyramid.
Step 2: Draw a shape on paper.
The drawing should fit on a piece of printer paper, but not the whole page.The template will be used to make the actual drawing of your shape.The drawing should be as close to your desired shape as possible.You can trace a shape using an object or another image.
Step 3: Use a ruler to measure and record your drawn shape.
You can record both the height and width of the shape you have drawn.If you draw your shape to scale, skip to Part 2 Step 4.If you need to rescale your drawn shape to your desired size, the steps in-between are necessary.From the highest and widest points, measure your shape's height and width.
Step 4: Determine the dimensions of your shape.
Decide on the width, height, and depth of your final foam shape.When working from your drawing's dimensions to your desired dimensions, keep the height and width ratios the same.This makes sure that your drawing is scaled correctly.
Step 5: You can draw a grid of squares over your shape.
To make sure your squares are the same size, use a ruler to draw them.The squares can be any size you choose, but commit to one sized squares throughout the grid.Even if the squares are partially cut off, draw them to the end of the page.
Step 6: Draw key points on your gridded shape.
Pick points that correspond to sharp edges, curves, high points, and low points.You will connect a scaled version of the dots to create a drawing.
Step 7: To rescale your drawn shape, you need the conversion factor.
The conversion factor is how you measure your drawing's dimensions.The conversion factors for both dimensions are the same because the ratio of height to width is kept constant.Pick the height or width you recorded from the drawing.Make sure the recorded value and desired value are in the same units.The recorded value times are equal to the desired value.You can get the value of the recorded value by dividing it by the desired value.For this step, a calculator may be helpful.If there are many decimal places, round to the nearest hundredth.
Step 8: A new grid with squares is drawn.
The scaled version of your grid is called the new grid.If you want the height and width of your squares for the new grid, you have to use a formula.You should draw the same number of squares.Depending on the size of your grid, you may want to use larger pieces of paper to draw it.
Step 9: On your new grid, redraw your key points.
The original grid should be the location of points on your new grid.If you drew a point in the middle of the left lowermost square on your original grid, you would draw the same point on the new grid.
Step 10: To create a new shape, connect the key points from your original drawing.
If this is difficult, you may want to draw more points on the original grid and transfer them to your new grid.
Step 11: You need to cut out your new shape.
The shape's lines should be cut as closely as possible.
Step 12: Put your shape on the foam.
Make sure the block of foam is large enough to hold the entire shape.
Step 13: Attach the shape to the foam.
To trace around the cut-out shape, use the black permanent marker.The number of shapes you trace out depends on the depth of the foam.The traced shapes will be attached to produce your desired depth.The number you get is the number of tracings you need to make.Round the number up if it isn't whole.It can be melted off later.
Step 14: Plug the electric hand saw in.
The area where you will be cutting the foam has an electrical sockets near it.Follow the safety procedures in the electric saw's instruction manual.No foam pieces will enter your eyes while you are cutting, so wear safety glasses.
Step 15: The foam shapes can be cut out with a electric saw.
Cut along or just outside the shape's lines.Fine details can be made using the hot wire foam cutter.
Step 16: You want to attach the foam shapes with spray foam.
The cross-sections of the shapes that will be attached should be sprayed with a light layer of glue.There is a blue spray in the picture.After spraying one foam shape's cross-section, gently lay the foam on the other side with no glue.The foam will stick to anything it is put on.The cross-sections of the two-shapes will be sprayed in under a minute.The cross-sections will not stick to each other if the two are clasped together.
Step 17: Attach the cross-sections of the two foam shapes to each other with foam.
When the foam is sprayed, it takes about 1 minute for it to dry, so quickly that you need to clasp the two cross-sections together.Continue to hold the foam pieces together until 30 seconds have passed to make sure they don't break.Attach foam pieces to each other with the foam attachment step.
Step 18: The hot wire foam cutter has to be plugged in.
The area where you will be melting the foam is near an electrical sockets.Follow the instructions in the hot wire foam cutter's manual.Plug the electric saw into the electrical sockets for your hot wire foam cutter.The electric saw won't be used again.Place the foam cutter on an item that is heat resistant.If the foam catches fire, keep an extinguishing agent near you.
Step 19: To melt it, place the foam cutter on your foam shape.
The foam cutter will melt through the foam very quickly if placed lightly.You are done once you have melted the shape you wanted.If you want to melt your foam in a well-ventilated area, wear a respirator because the fumes released by the melting foam are potentially toxic.The foam will not be over melted if you use small and fast strokes.