How to cut foamboard

A cutting mat with a metal safety rule, scalpels and a utility knife

What you need

A cutting mat with a metal safety rule, scalpels and a utility knife

What is foamboard?

Foamboard is a layer of foam sandwiched between two layers of card. It comes in a range of thicknesses and is mainly available in black or white.

The edge of a white foamboard sheet, showing the foam between two layers of card

Cutting

You cut foamboard in the same way you cut card. Using a safety rule and a sharp knife, keep the blade as vertical as possible and steadily work your way through the foamboard, making as many cuts as necessary.

Cutting white foamboard with a scalpel held upright against a safety rule

The key to a clean cut

The blade of your knife must be very sharp. A blunt knife will drag through the foam core and leave a very ragged cut.

Cutting a clean strip of foamboard against a safety rule

A neater edge

To join two pieces of foamboard at a right angle, remove the top layer of card and the foam core along the joining edge, but leave the bottom layer of card. The width you remove should be the same as the thickness of the foamboard.

Cutting away the top card and foam along the joining edge of a piece of foamboard

Remove the cut section

Run your blade along the inside of the bottom card layer to remove the section. You can now bring the two pieces together for a perfect edge.

Two pieces of foamboard joined at a right angle with a neat edge