How to cut polyethylene foam sheets

Written by kimberly johnson
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Polythene foam sheets, which are more commonly called PE foam, are used mostly in product packaging as cushioning. Its lightweight and semi-waterproof qualities make it a popular choice for flotation devices and swimming pool toys. In thinner layers, the foam is wrapped around furniture items to prevent them from getting scratched during shipping.

Skill level:

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Things you need

  • Safety glasses
  • Marker
  • Table clamp
  • 1/16-inch diamond or carbide saw blade
  • Table saw

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  1. 1

    Put on safety glasses to protect your eyes from small pieces of flying foam. You do not need to wear a dust mask, since polythene foam does not create dust when cut.

  2. 2

    Lay the foam sheet on a flat work surface. Draw a line on it where you want to cut.

  3. 3

    Secure the sheet to the work surface with table clamps. Make sure that the cut line hangs off of the table by at least 1 inch to allow you to cut the foam without cutting the work surface.

  4. 4

    Install a diamond tip or carbide saw blade into a handheld electric saw or table saw. The best blade to use is a 1/16-inch with 1.25 teeth per inch of blade.

  5. 5

    Turn the saw on and push it slowly across the marked line on the foam until you have cut all the way through it.

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