How To Cut Polystyrene

Polystyrene is a commonly used material in the field of crafting, construction and packaging. It's lightweight, inexpensive, and easy to cut. However, for beginners, cutting polystyrene sheets or blocks can turn out to be a daunting task. But don't worry, with the right tools and techniques, cutting polystyrene can be a breeze.

Tools Required

Before starting, you need to gather the following tools:

• A sharp utility knife or box cutter.
• A straight edge such as a ruler or a T-square.
• A cutting mat or a thick piece of cardboard.
• A fine-grit sandpaper or a sanding block.
• Safety goggles.

Techniques:

Method 1: Cutting with a Utility Knife

Cutting polystyrene with a utility knife is one of the easiest and most common methods. Here's how:

1. Take measurements of the piece you need to cut.
2. Using a straight edge, mark the lines to make your cuts on the polystyrene sheet/block.
3. Press down firmly with the utility knife, and score the polystyrene along the lines you drew while holding the straight edge in place.
4. Repeat this process several times to make a deep groove that will make the final cut easier.
5. Hold the polystyrene along the scored line and snap it with a quick motion to complete the cut.
6. Use the fine-grit sandpaper or sanding block to smooth any rough edges.

Method 2: Hot Wire Cutting

This method is particularly useful for making intricate cuts or shapes in polystyrene:

1. Set up a hot wire cutter on a workbench or table. You can purchase a hot wire cutter from any large hardware or craft store.
2. Measure and mark the lines you need to cut on the polystyrene.
3. Heat up the wire on the hot wire cutter, following the manufacturer's instructions.
4. Place the polystyrene sheet/block underneath the wire and guide the wire along the lines that you have marked.
5. Move the cutter slowly to prevent the wire from bending or breaking.
6. Smooth out any rough edges with fine-grit sandpaper or a sanding block.

Precautions:

While cutting polystyrene, keep in mind the following precautions:

• Do not use a saw, as this can cause the polystyrene to melt and stick to the saw blade.
• Wear gloves to avoid getting cut by the polystyrene edges.
• Always work in a well-ventilated area because melting polystyrene emits fumes that are harmful to breathe.
• Lastly, be cautious while using a hot wire cutter as the wire can become extremely hot and potentially cause burns.

Conclusion:

Cutting polystyrene may seem daunting at first, but with the right tools and techniques, it's easy and hassle-free. The methods mentioned above can make your polystyrene cutting experience a smooth one.