Electric Carving Knives

I recommend a common electric carving knife for working with foam. It is fast and efficient. It is also relatively inexpensive ($10 at WalMart).

I do not recommend "hot wire" carving. This is when foam is cut with an electrified wire that melts its way through the foam. This process releases a lot of very nasty chemical byproducts as the foam is heated.

Choosing Your Foam

Foam has the advantages of being lightweight, easy to work with, and relatively inexpensive. The weight and stiffness can vary based on the foam you choose.

The stiffness of the foam affects how well it will carve. Foams that are very soft and quishy can bend under the knife rather than being cleanly cut. This results in wavering lines, rapidly-dulling knife blades, and rapidly-fraying nerves.

Foams that are stiffer are usually denser. Weight isn't likely to be a serious problem unless you are creating either a very large foam structure or something that is cantilevered or suspended. For heads, consider that this foam will be in close contact with your skin; avoid the stiff foams that are itchy or abrasive.