Foam Laser Cutting Machine

[merkava74]

Curious if this topic has ever been discussed?

What is the feasibility of owning a laser cutting machine for foam cutting? Let me kick off the pros and cons, feel free to contribute to the discussion!

Pros:

1) Clean cuts
2) Accuracy
3) Speed
4) Consistency for multiple copies

Cons:

1) Cost
2) cannot do bevelled cuts?

Would love to hear from those that own machines or have used them for pepping foam. Do quote the models used as well as the price if possible to provide a sensing, thanks!

 

[Contec]

Big con
"toxic fumes"
"Possible to damage the laser because of the melted foam sticks to laserparts."

 

[Bloop]

I would think a hot wire foam cutter or even an electric carving knife would be better, cheaper options (depending on the type/density of the foam). I don't think a laser cutter would be worth the cost. Plus, the laser cutter would have to be large enough to accommodate fairly big pieces of foam, if you plan to use it to make costumes, so the cost would probably be even higher for a machine that size. The lowest cost machines I found online were $650, and they seem like they're mostly for engraving, (though you probably can do cuts as well).

You can make your own hot wire foam cutter for cheap. Instructables has a DIY one that cost about $30 for parts, though it can be cheaper, especially if you have some spare parts around the house. You still run into the problem of fumes, though. Google it, you'll find several DIY options if you're interested.

 

[merkava74]

Fumes will definitely be a concern. Not sure how the control measures like fumes extractors and exhaust will help in an enclosed space. That is definitely a point to consider. Not quite understanding how the laser would be degraded though?

I was looking at a laser cutter to provide a clean accurate cut as compared to a hot wire cutter, which is still essentially freehand. And yes you would probably need a cutting table in the area of "20 X "20 I guess.

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[epilepticsquirl]

Not quite understanding how the laser would be degraded though?

PVC, when heated, releases chlorine gas. Chlorine gas, aside from having that funny lethal side effect, is corrosive and will damage the inside of a laser beyond repair over a period of time.

And now you know. :thumbsup

 

[merkava74]

Wow. What's the shelf life then? What about those companies that deal in foam? Wouldn't they be replacing their lasers very frequently?

I mean, if I need to replace a laser every 2 years, that sounds alright....

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[merkava74]

PVC, when heated, releases chlorine gas. Chlorine gas, aside from having that funny lethal side effect, is corrosive and will damage the inside of a laser beyond repair over a period of time.

And now you know. :thumbsup

Thanks. Useful info on how not to turn my house into a gassing chamber.

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[jayart05]

Just to give you an idea of how toxic this foam is...my method of heating my foam cutouts in the oven at 300 degrees for 30 seconds to 1 minute was ok when I was doing maybe 1 piece a day....but the last two days before comic con...i did about 5 - 6 pieces per day...

The next three days...I had a migraine and body fatigue

The gas that foam releases is no joke

Now I know thumbsup