Foam Carving

Foam carving for set building is used for texture, decor, handprops, etc. It is used because you can make anything you can dream of and it is still light weight for stage techs and actors to use. For example, if an actor needs to lift a heavy rock during a show, instead of using a 50lb rock or even a mold that weighs 10lbs, you can use a 5lb piece of foam. It just requires more work on the acting side of things. Another example would be a set piece which requires a textured exterior, such as wood, siding or stucco. Instead of using the actual material which would weigh the set down and make it difficult to be moved around on stage and off, you could use foam, and have the same effect and it would be much lighter.

Foam also comes in different mediums, such as sheet foam, spray foam, and cushion foam. Spray foam can be found in cans, like the ones you see at the home depot, and in canisters, which look like little propane tanks. The canisters of foam are typically for larger jobs. Spray foam when sprayed will adhere to the surface it is sprayed on and it will expand. Once it is dry it can be carved to the shape you would like it to be. Sheet foam can be purchased at any hardware store. It is comes as thin as a quarter inch to as thick as you would like to find it. For theatre sets you probably don't want it thicker than 2 or 3 inches. Sheet foam it is mostly used for texture, such as, stucco on a building, wood boards, siding, stone or brick. The other foam medium commonly used is cushion foam. This can be used for a fall mat. For example, if an actor has a fall scene or fight scene which they get shoved against something or taken to the ground, instead of them hitting a hard surface we can disguise the floor, rock, tree, log, anything by carving a cushion foam piece. Lets face it, if you had to fall on a hard surface 2 or 3 times a day 5 or 6 days a week you would probably get a little bruised or sore after awhile.
How to carve the foam can be as simple or complex as you want it to be. A more simple approach would be using a really sharp smooth blade butcher knife. I say really sharp because even though foam is a soft medium it will dull your blade and when it dulls your project and your wrist begin to get painful. Other simple ways are using sanders, drummels, and reciprocating saws. Once you have your pattern and/or texture planned out (this is very important because once the foam is gone it is hard to replace it) using one of these power tools will speed up your process. The simpler way of carving is very helpful for schools and venues on a smaller budget. If money is flowing freely then you can get into the computer graphics and laser carving. With this skill your possibilities are endless and fine detail can be achieved. My experience with this form of foam carving is not as great but I encourage you to look it up. It can be really cool to see. Here is a link for a company called Frog 3D. http://www.youtube.com/watch?v=MzGh5xmNpAs