Props, Scenery, Costumes and Makeup: Foam.

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Foam.

Printed From: Community Theater Green Room
Category: Producing Theater
Forum Name: Props, Scenery, Costumes and Makeup
Forum Discription: For how-to's and where-can-I-find
URL: http://www.communitytheater.org/forum/forum_posts.asp?TID=5184
Printed Date: 10/31/25 at 1:20pm
Software Version: Web Wiz Forums 8.05 - http://www.webwizforums.com

Topic: Foam.

Posted By: jt7724
Subject: Foam.
Date Posted: 10/16/11 at 12:55pm

I find foam to be an incredibly versatile and useful material when it comes to prop (and set) making, and lately I have been using it and seeing it used more and more. Since foam seems to have an endless array of carving techniques, finishes, uses, etc. I would like to open this up to anyone who has something useful and interesting to share about this miraculous substance.
Some creative way you have used it?
Your favorite way of carving or shaping it?
A lesson you have learned the hard way that you want to pass on to others?

I am dedicating this post to foam that magical substance without which theater (especially community theater) would be lost.

Replies:

Posted By: JoeMc
Date Posted: 10/19/11 at 8:03am

Sorry jt

I for one use it very rarely, because it perpetuates it"s own flame, can be a problem putting out & gives off toxic fumes.

Even if you jesso it with calico or canvis & treating with fire retardant.

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[western] Gondawandaland
"Hear the light & see the sound!
TOI TOI CHOOKAS
{may you always play to a full house!}

Posted By: SamD
Date Posted: 10/19/11 at 2:01pm

We sometimes use the pink sheets for cove molding and baseboards. It cuts really nice with a table saw - and it's light weight!

Posted By: ZFix2000
Date Posted: 11/13/11 at 11:02am

       I have used both polystyrene and Styrofoam for many, many props and sets. I have made everything from replicas of old sewing machines for "The Pajama Game" to an 8' X 12" Sphinx face for "Joseph and the Amazing Technicolor Dreamcoat" out of 2' x 4' x 8' styrofoam blocks. For both I have made my own styrofoam heat knife. This I use to make initial large cuts. Then I use a Surface Forming Multi-Rasp Shaver, the small plastic handled, removable blade kind, for rough shaping. For the polystyrene I use a fine sand paper to get a very smooth finish. The styrofoam will not ever get this same finish due to it's composition.
       You can make virtually anything you want out of the stuff. When using a heat knife or power tool with it, you MUST have proper ventilation and wear a respirator. Because when heated it releases harmful dust and vapors. You should use a respirator when sanding the stuff also since the fine dust can get into your lungs and cause numerous issues like a Heart Trauma ( this from experience is not very nice. ) The dust clogs your lungs and basically causes a heart attack that is not due to heart related medical issues. In my case I carved and sanded an entire laced wood looking set for "The Sound of Music" in a shop with no ventilation and did not wear a mask. It put me out of commission for a few months but luckily there was no permanent damage.
      To make the foam thicker or attach it to things or things to it,you can use "Spray 70" for styrofoam or "Spray 80" for polystyrene. This is a spray contact cement. The number indicates strength and for the foam lets you know how much it will eat it away. If used according to the instructions, it will bond the pieces as one. But a warning, like all contact cement, once it touches it is GLUED and cannot be moved. So to make a thicker working piece, I cut them to rough size and glue them before carving. The glue will not carve at the same rate so do not try to smooth seams with rasp. Gently sand the seams as good as you can. Once sealed and painted they will not show.
      To help the finished product withstand some abuse I base coat it with Snow Roof. A white elastic latex paint. Then you can give it any treatment you desire including spray paint, which without a latex base coat would eat the foam.
      I LOVE the stuff.

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If You Can Dream It I Can Create It