How to cut polyurethane foam

Updated April 17, 2017

Polyurethane foam is most commonly found in the form or swimming pool supplies. Polyurethane foam can also be used to insulate the walls in your home. Polyurethane foam can reduce noise through thin walls and help keep a controlled temperature inside a room. Things like electronics or other fragile objects are often packed with polyurethane foam to prevent damage. Polyurethane foam can be cut to size using a utility knife, router and hand saws.

Use a utility knife to cut your polyurethane foam to shape. Extract the blade from the knife by using your thumb to push the blade lever up toward the top of the knife. Press the blade into the foam and run the blade down the foam making your preferred cut. Depending on the thickness of your polyurethane foam, a utility knife might not cut deep enough. If this is the case, flip the foam over and use the utility knife to cut the other side, following the same cutting path.

Cut the polyurethane foam using a hand saw. Place the foam on a saw horse to allow space for the saw to cut through the foam. Place the saw at the edge of the foam where you wish to cut. Angle the hand saw at a 45-degree angle and move your arm back and forth to cut the foam. The more teeth on the hand saw, the cleaner your cut will be.

Use a hand-held router with a steel or carbide cutting tip to cut shapes in the centre of the polyurethane foam. Set the hand-held router on top of the foam in the area where you wish to cut in the centre of the foam. Flip the power switch and guide the hand-held router to design and cut shapes in the centre of the foam.


Always use safety goggles to protect your eyes from flying debris.

Things You'll Need

  • Hand saw
  • Utility knife
  • Hand-held router
  • Saw horse
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About the Author

David Shaw has been writing professionally since 2006. He has featured music-related articles in "Connections" and "Axis Magazine." Shaw attended Florida State University where he majored in communications and he was granted a certificate of completion from Full Sail Real World Education for the recording arts program.