Foam-Core Prototyping

GETTING YOUR IDEAS OUT OF YOUR HEAD AND INTO

THE REAL WORLD.

Prototyping
It is necessary to be able to convey your ideas to

others effectively.
A picture is worth a 1000 words . . .
. . ., but a three-dimensional prototype is most often
needed.
A prototype:

is inexpensive
is quickly made (in comparison to the final product)
represents the proposed product or device

Types of Prototypes
There are several types of prototypes:

Concept drawings (simple sketches to get the ball rolling)

Virtual computer simulations (like Solid Edge)
Mathematical models (MathCAD, MatLab and Excel)
Clay models (often seen in the automotive industry)
Foam-core (like the one you are about to make)

Some prototypes are fully functional,

but many are just spatial representations.

Foam-Core
Foam-core (or Foam Board) is one material that can

be used for quickly prototyping your ideas.

Foam-core is a composite material consisting of:

An outer layer of card stock

And inner layer of foam (like Styrofoam)
And another layer of card stock

Tools for Working with Foam-Core

Only a few basic tools are needed for Foam-Core:

Cutting mat (so you dont cut up the table top!)

Cutting knife (Exacto, or box cutter) with a sharp blade
Metal ruler (for measuring and making straight cuts)
Pencil or a pen (for marking the cut lines)
Tape (clear packing tape works well)
Hot glue can be used also, but not required (low-temperature!)

Getting Started with Foam-Core

Make sure you have a good, solid surface to work on

and BE SURE TO USE THE CUTTING MAT!

Lets start with just cutting a straight line
Since foam-core has three layers, it is usually best to
make three cuts:

Cut through the top layer of card stock

Cut through the layer of foam
Cut through the bottom layer of card stock

If you try to cut through all three layers at once, you

will end up with a jagged mess!

Cutting a Line
First, measure and mark the line.

You may want to start at the 1 mark on your ruler, as the scale
on some rulers does not go all the way to the end.

Be sure your fingers are out of the way!

Make the THREE cuts.

from
Measuring
k.
the 1 mar
Finge
rs
the cu out
t t in g
path.

you
With three cuts,
get a really nice
edge!

Types of Corners
At some point you are going to want to join your

foam-core pieces together there are at least three

types of corners that you can make:

Overlapped
Mitered
Rabbeted

Overlapped

Mitered

Rabbeted

Overlap Corner
The overlap joint is the simplest corner to make.
Simply cut the two pieces and tape them together to

create the corner.

It helps to lay the tape down (sticky side up) on your
work surface and place the first piece of foam-core
on top of the tape.

Miter Corner
Mitering a corner makes for a nice clean outside, as

there is no break in the material.

Cut a V-shaped groove in the foam-core.
The angle of the V determines the angle of the
resulting corner.

e.
The V-groov

Angle the c
utting knif
e to
create the
groove.

Rabbeted Corner
The rabbeted corner gives a nicer looking corner

than the overlap, and is easier than making the

mitered corner.
Cut through one layer of cardstock, and the foamcore, but not through the other layer of cardstock.

Only cut through two

layers of the foam-core.

Cut at 90-degrees from

your first cut to form the
rabbet.

A rabbet!