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Best Practice for Cutting Foam with a Laser

Laser cutting foam is a great way to create clean, precise custom shapes, toolbox inserts, and props. For best results...

Cutting Foam Report CLICK HERE FOR COMPLETE PDF ARTICLE

GCC Cutting Foam Video   |  GCC What kind of Materials can I cut?

Laser cutting foam is a great way to create clean, precise custom shapes, toolbox inserts, and props. For best results, use laser-safe materials like EVA, polyethylene (PE), or polyurethane (PU) foam. Always avoid polystyrene (Styrofoam) and PVC foams, as they are toxic and pose a severe fire hazard.

Best Practices for Laser Cutting Foam

  • Material Choice: EVA foam (often found as floor mats or craft sheets) and Shadow Foam are the most popular and laser-friendly choices.

  • Laser Type: CO2 lasers are highly efficient and produce the cleanest cuts.

  • Air Assist & Extraction: Foam vaporizes when burned. Always use high air assist to prevent flare-ups and ensure you have proper ventilation or Purex fume extraction to handle the odors.

  • Focus & Speed: For thicker foam, you may need to drop your focal point slightly below the surface of the material rather than directly on top. Using multiple, faster passes is generally much better than using one slow, high-power pass, as it prevents the edges from burning or melting away. We recommend using a four (4) inch lens and use multiple passes to prevent flaming.

  • Cutting Order: If you are cutting out shapes and an outer border (like a tool insert), ensure your design software is set to cut the internal shapes first. If the main perimeter is cut first, the material will shift and ruin the accuracy of your internal cutouts.

  • While Cutting: do not leave machine unattended such as going out to lunch or going home as this material can easily flame. We recommend using some type of fire\flame detection system such as Jorlink's SmartGUARD™ Fire Alarm (Patented) which assures optimum safety. When there is a malfunction, the alarm system will be active and shut-down the laser tube power immediately.

Recommended Starting Settings (Baseline)

Settings will vary heavily based on your specific wattage, lens (4” lens recommended), and foam density. Always run a small test grid before committing to a full design.

  • CO2 Laser (e.g., 60W, 80W, 100W+) for 1/4" to 1”+ EVA Foam:

  • Speed: 15 mm/s to 30 mm/s

  • Power: 70% to 100%

  • Passes: 1 to 3 passes (depending on thickness and machine model)

GCC Foam Cutting Video