Can a Foam Pool Float (shiny vinyl sided) be smoothly cut somehow?

Question

I want to make sailboat cockpit cushions out of this material and need square and smooth edges. I wonder if a hot knife or

electric meat cutter could do this job?

Cheers & Thanks

Answer 1

Hot knives are used to cut most original pieces of foam into their final shapes. So yes, a hot knife will create a very clean edge. Using a serrated blade is a bad idea, as it will cause the foam to flake away in unpredictable ways, preventing a clean line. Straight bladed knives should work just fine, but may result in exposed foam cells, leaving an ugly, exposed edge.

Some foam products have thin plastic coverings which may melt back once heated. Make sure that the foam product you are cutting is a closed-cell foam without any outer coverings to prevent any complications. You'll know that it's closed foam if you tear a piece of it off, revealing even color throughout, and if the exposed inner part doesn't absorb any liquids.

    I've seen several blue pool loungers made of closed cell foam. They got a thicker, heavier feel, that is very elastic. Those are a pretty safe bet on being appropriate for your needs.

  Working with foam can be tricky, make sure that your hot knife doesn't burn away the parts of the foam you want to keep or causes excessive shrinking.

  You might also order neoprene (a type of closed-cell foam used in maritime products) or other foam sheets from an internet based sound dampening company. They come in a variety thicknesses. I know you just want to sit on it, but neoprene is used a lot for sound dampening as well as for cushions, so don't be afraid of buying it from a company that mostly sells speakers.

I've found that it's easiest to cut neoprene with scissors or a straight bladed knife. Even a pizza cutter will work.

Let me know what you end up doing.