Foam Cutting Services

Giant foam letters, custom logos, and sculpted props — cut cleanly and at scale.

At 865FabLab, we specialize in advanced hot wire foam cutting for signage, packaging, architectural molds, and large-scale props. Our production-grade machine can operate with up to 10 hot wires simultaneously, allowing for efficient, high-volume foam processing — from giant foam letters to custom foam packaging inserts.

Foams We Cut

Ideal for Hot Wire Cutting

Expanded Polystyrene (EPS)
Extruded Polystyrene (XPS)
Polyethylene (PE) / Ethafoam (with caution)
Expanded Polypropylene (EPP) (case-by-case)

Not Suitable for Hot Wire

Polyurethane (PU) — toxic fumes
EVA Foam — sticky residue, poor cut quality
Spray Foam — safety hazard when heated

We only cut foams proven to perform cleanly and safely on a hot wire system.

Cutting Capabilities

Multi-wire hot wire foam cutting with up to 10 active wires at once
Max cutting size: Up to two foam buns (4' × 4' × 8') processed simultaneously
Contour and profile cutting with bevels, arcs, and radius details
Precision-cut 3D foam logos and sculptural forms
Clean, sealed-edge cutting with minimal mess or dust
EPS mold production for precast or cast-in-place concrete
High-speed output for repetitive parts or multi-cut layouts

Applications

Giant Foam Letters — perfect for malls, photo ops, and activations
Foam Sculptures & Props — for trade shows, themed spaces, and marketing displays
Custom Foam Logos — dimensional branding elements for exhibitions or retail
EPS Molds for Concrete — durable forms for architectural or specialty concrete
Foam Inserts & Packaging — for fragile items, drones, tech gear, and military cases
3D Display Builds — assembled pieces for set design, backdrops, and structures
Moss Wall Displays - We fabricate custom foam structures as a lightweight base for preserved or artificial moss walls — perfect for branded installations, green-themed displays, and scenic environments.