wrote in message
...

I would like a tool for freehand cutting 1" and larger fonts into blue 1/2
inch
Styrofoam.
Something fast and leaves a clean edge.
there are hot blades and then those little 12 volt jigsaws for gourd
carving but
I've never seen either.
Anyone have experience cutting fine patterns in sheet Styrofoam, mostly
lettering.
thanks

Drill press with an end mill for the cutter. Layout the letters, bring the
bit down and lock it, then move the foam around. You need a fairly large
table for it. It is also good to have some air blowing away the dust. The
dust is a real PITA as it is very clingy with static electricity. After
cutting, touch up can be done with sandpaper and the usual sanding blocks
for corners, etc.

We use an old Walker Turner DP for this but any can be use on a fairly high
speed. It is the first choice for people that make pre-production samples
of this type of material for a living.
--
Ed
http://pages.cthome.net/edhome/