Hello. I am in the process of making a series of decorative wooden boxes to store and display optical equipment. I am interested in any good ideas to improve my ability to cleanly cut foam inserts to specific complex shapes to accomodate these items. This is the sofer sort of foam rather than the firm foam like styrofoam that cuts so well with a hot wire.
In the past, I’ve tried a variety of methods including cutting the foam in layers with a utility knife, sawing, etc. Unfortunately, things never come out as crisp and clean as I would like. I’ve also heard tales of freezing the foam to stiffen it and make the cutting cleaner, etc.
Any great ideas for accomplishing this for those of us that don’t have a CNC foam cutting machine….
Thanks in advance.