How to Cut Foam with Precision and Speed: Solving the Biggest Challenges in Foam Cutting
May 28, 2025
Whether you're creating protective packaging, display signage, or custom inserts, foam can be one of the most difficult materials to handle in a production environment. It compresses, distorts, and often refuses to cooperate with traditional cutting methods—leaving behind frayed edges, dust, or inconsistent results.
At Kongsberg Precision Cutting Systems, we know the challenges professionals face when cutting foam. And we’ve engineered the solutions to help you overcome them.
In this article, we’ll walk you through exactly how to cut foam with precision, speed, and confidence—using the right equipment, tooling, and techniques. If you're looking to streamline your production, reduce waste, and deliver clean, professional results every time, you're in the right place.
Foam may seem simple, but in the cutting world, it's deceptively complex. Its unique properties—flexibility, compressibility, and varying densities—make it difficult to achieve a consistent, clean cut
using traditional tools. Whether you're working with high-density closed-cell foam or soft, spongy PU foam, each material type demands a specific approach.
Challenges include:
These problems can add hours to your workflow, increase waste, and hurt your bottom line. That’s why more and more professionals are turning to automated foam cutting solutions.
At Kongsberg PCS, we specialize in digital cutting systems designed to take the pain out of foam cutting. Our solutions combine precision hardware, intelligent software, and dedicated tooling to help you cut foam cleanly, safely, and at high speed.
Let’s dive into the tools and systems that make this possible.
The Foam Cutting Unit is the go-to solution when you need power, performance, and clean results. Equipped with a fast-reciprocating knife, the FCU is designed to cut through thick, rigid foam materials without tearing or compressing the surface.
Key benefits:
With the FCU, you'll handle even the toughest foam jobs with ease—without sacrificing edge quality or throughput.
For ultra-thick or high-performance foam applications, the FoamHead brings unmatched capability to your cutting table. This heavy-duty tooling module is engineered specifically for cutting high-density industrial foams and excels in packaging, protective inserts, and signage applications.
FoamHead features:
This tool is ideal when cutting dense foam for protective cases or detailed structural packaging.
Many foam applications also involve combining foam with rigid board materials like corrugated plastic, PVC, or display boards. Our cutting systems are built to handle these as well.
With automatic tool changing and multi-zone vacuum beds, a single Kongsberg table can switch from soft foam to rigid board in seconds. This means:
Whether you're cutting foam liners, rigid outer shells, or everything in between—our systems give you complete flexibility.
Here’s how we help you tackle your foam cutting challenges head-on:
Our systems come in a range of sizes and configurations to fit your exact production needs. Whether you're a high-volume packaging specialist or a small-scale sign shop, we’ll help you configure the right table, tooling, and workflow.
Popular systems for foam cutting include:
Foam doesn't have to be frustrating. With the right equipment, you can turn this challenging material into a reliable part of your production process—cut cleanly, efficiently, and exactly the way your customers expect.
At Kongsberg PCS, we're committed to helping you shape your future with innovative tools and tailored solutions that keep you one step ahead.
Get in touch today to explore our systems and see which solution is right for your materials, your team, and your business goals.
Get in touch with one of our experts. We're here to help you cut smarter, faster and better.