How to Carve Flexible Polyurethane Foam Sheets

Written by crystal gafford
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How to Carve Flexible Polyurethane Foam Sheets
Flexible polyurethane foam can easily be carved into almost any shape imaginable. (blue foam image by Dave from

Flexible polyurethane foam is a versatile material used in many products. Polyurethane foam can be found in upholstered furniture and mattresses. It is also widely used to create costume accessories. The flexibility of the material makes it easy to bend a shape instead of having to carve all of it, but this soft material is fast and easy to carve with patience and some simple tools.

Skill level:

Things you need

  • Permanent marker
  • Electric carving knife
  • Steak knife
  • Scissors

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  1. 1

    Draw the shape you want to carve onto the foam with a permanent marker.

  2. 2

    Carve out the rough shape with an electric carving knife or a steak knife. Serrated edges are best for slicing through flexible foam.

  3. 3

    Trim rough edges and smooth your shape using scissors. Take tiny snips out of the foam until the shape is perfected. This step is the longest and most painstaking, but the results are worth it.

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