Material Blog

Laser Cut Foam: Unlocking Your Creativity

Can you laser cut foam?

Laser foam has become the go-to solution for precision and innovation across multiple industries. EVA foam, with its remarkable shock-absorbing, sound-insulating, and thermal-insulating properties, has transformed the world of sports equipment, household appliances, fitness gear, shoes, and crafts.

The fusion of these two materials unleashes a world of opportunities, making them an ideal choice for sports equipment, household appliances, printing, fitness gear, shoes, and crafts. Laser machine is the best tool to laser cut foam.

Laser cutting foam is the secret sauce that elevates EVA foam to a whole new level of creativity and precision. Its accuracy and versatility make it the perfect tool to shape and cut this soft yet sturdy foam. The laser cut foam application extends far and wide, encompassing multiple industries, leading to a burgeoning market for laser sales.

What types of foam are suitable for laser cutting?

Various types of foam can be laser cut effectively, depending on their composition and intended use. Here are some common foam for laser cutting:

1. Polyethylene foam (PE foam)

Known for its durability and resistance to chemicals, PE foam is ideal for creating protective packaging, case inserts, and gaskets.

2. EVA foam

Lightweight and flexible, EVA foam is popular for crafting, cosplay props, and padding applications. It cuts cleanly with a laser, creating smooth edges.

3. Polyurethane foam (PU foam)

This versatile foam is used in furniture, soundproofing, and custom inserts. It can be laser-cut for intricate designs but may require proper ventilation due to fumes.

4. Polystyrene foam (Styrofoam)

Commonly used in displays and lightweight models, it is suitable for laser cutting with low power to avoid melting or distortion.

Laser cutting foam projects and ideas

Foam is an ideal material for laser cutting due to its lightweight nature, flexibility, and ease of cutting into various shapes. It’s suitable for creating custom packaging inserts that provide cushioning and protection, intricate stencils for crafts or signage, and decorative elements such as holiday ornaments or themed props. Here are some common laser cutting foam projects and ideas:

©Jeff Pearson

Foam boards in various colors can be assembled to create vibrant, eye-catching signs that highlight unique logos and designs with smooth, polished finishes.

©Jeff Pearson

The unique texture of foam lends itself perfectly to creating textured and artistic pieces. Once painted, these can serve as creative and striking holiday decorations.

©Jeff Pearson

Foam can be custom-designed to fit the size of packaging boxes and the items inside. Its soft material effectively absorbs shocks, reducing the risk of damage during transportation.

Explore our sample library for more exciting laser engraving and cutting ideas, along with free files!

Eva foam or polyurethane foam, which one is better?

Now, let’s tackle the question of whether to choose EVA foam or Polyurethane foam for your laser-cut foam projects. While these materials may appear similar, they serve different applications in the world of laser workmanship.

EVA foam, lightweight, flexible, and non-toxic, is the ideal choice for creative projects like crafts, role-play props, and packaging. On the other hand, Polyurethane foam, known for its durability and wear resistance, is more suited for industrial and commercial applications such as insulation, protective packaging, and even house heating solutions.

When it comes to laser cutting foam, EVA foam has more advantages than Polyurethane Foam. It requires lower power settings, resulting in cleaner cuts and reduced heat accumulation compared to Polyurethane foam.

Where to buy?

The next natural step is to find sources for your laser-cut foam materials. Fortunately, you have several options to explore:

A popular choice for many, Uline offers a variety of laser-cut foam sheets and materials to cater to your needs. Explore their selection here

With 80 stores across the United States, Polymershapes provides a wide range of foamboard and paperboard options, ideal for laser-cut foam projects. Check out their offerings here

For a wide variety of foam products and customizable solutions, Foam Factory is your go-to source for laser-cut foam.

Choosing a perfect laser foam cutter for you!

To choose the perfect laser model for your foam cutting projects, consider the Thunder Laser Nova and Bolt series. CO2 laser machines are highly effective for cutting foam boards, and Thunder Laser’s models deliver clean and precise results on foam materials.

The Thunder Nova excels with its higher laser power and larger work platform, making it a powerhouse for demanding projects. It’s an excellent choice for cutting larger foam boards or handling bulk tasks efficiently, especially if you have the space to accommodate its robust design.

The Thunder Bolt, on the other hand, is ideal for creative laser work at home. Its compact desktop size offers high engraving precision and can handle foam cutting tasks with ease. For even greater capabilities, you can upgrade to the Thunder Bolt Pro, an enterprise-level machine designed to help grow your laser business.

Your choice depends on your specific needs! Check out how customers use the Thunder Nova for foam board laser cutting. With Nova’s camera positioning system and LightBurn software, creating custom foam liners becomes simple and efficient.

Eva foam laser cutting settings

Now, let’s delve into the specifics of laser cutting EVA foam. Keep in mind that the cutting outcome can vary based on the foam’s origin, batch, and production method. Here are some general parameters to get you started, but you may need to fine-tune them for your specific laser-cut foam project.

Process	Thickness	Speed(mm/s)	Min Power(%)	Max Power(%)	Blow Type	DPI
Engraving	/	500	13	13	low	300
Cutting	10mm	45	10	90	high	2"
	20mm	22	10	90	high	4"
	30mm	7	10	90	high	4"

Check out our knowledge base for more material settings!

Tips and tricks for laser cut foam

1. How to maintain a clean cut when cutting foam?

Keeping the laser lens and mirrors clean is crucial for maintaining beam quality. Use air assist to minimize charred edges and regularly clean the work area to remove debris. Additionally, use laser-safe masking tape on the foam surface to protect it from scorch marks during cutting.

2. How do I laser cut foam thicker than 1 inch?

To cut foam thicker than 1 inch, you’ll need to use a 4-inch lens instead of the standard 2-inch lens to get better results. The longer focal length of the 4-inch lens allows the laser beam to maintain focus over the deeper material, ensuring a clean and precise cut. Using a 2-inch lens for thicker foam may result in scalloped or uneven edges due to the limited focal range.

3. What type of foam works best for laser cutting?

Closed-cell foam, such as polyethylene or EVA, often works best due to its clean cutting properties and reduced risk of melting. Avoid foams with PVC, as they release harmful fumes when cut. Always verify that the foam you’re using is safe for laser processing.

4. How can you process foam without causing it to melt?

Excessive heat can cause foam materials to melt. To avoid this, reduce the laser’s power and speed while performing multiple passes to achieve a deeper engraving or cleaner cut. You can also utilize the dot mode to minimize heat exposure on the material. Additionally, maximize the effectiveness of air assist to keep the cutting area cool.

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