Is it Safe to Laser Cut Eva Foam?

Using foam cutting and engraving as a business can be a lucrative endeavor.
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Ethylene and vinyl acetate are components of the copolymer known as ethylene-vinyl acetic (EVA) foam, also called polyethylene-vinyl acetate (PEVA). 

Machining EVA foam with a laser may be done using either a 9.3 nano or 10.6-micron CO2 laser with little to no discernible change in the overall quality of the procedure. EVA foam does not readily absorb the energy from a 1.06-micron fiber laser. Hence the usage of this laser with this material is not suggested. 

When cutting EVA foam with a CO2 laser, the resulting cut is broad and has a faint brown discoloration in certain places. Using a CO2 laser to perform laser engraving on EVA foam creates depth and a darkened surface, slightly sticky surface, and melted edges. It is not feasible to laser mark EVA foam with 9.3, 10.6, or 1.06-micron wavelengths.

What Exactly is the EVA Foam?

EVA Foam

The substance you are looking at is called EVA, and it is a black foam. Ethylene-vinyl acetate is a kind of copolymer that goes by the acronym EVA. 

This versatile foam that is both soft and hard can be readily laser cut with ZMorph VX, and it also has a wide range of uses, some of which will be discussed in the next portion of this article. 

EVA foam is characterized by very little water absorption and is soft, and has excellent shock absorption properties. We’ll show you how to use EVA when you attach the Laser PRO toolhead to your system and demonstrate how it works.

EVA Foam Laser Cutting and Engraving Machine:

Triumph 50w Fiber Laser:

Triumph 50w Fiber Laser

Product Specification

  • Work Area: 110 x 110 mm
  • Laser Speed: <9000MM/S
  • Laser Power: 50W
  • Rotary attachment: 80mm
  • Software: Triumph Laser software, Laser GRBL

In addition to the fact that any object may be engraved with designs using a laser, this method is also a very dependable and appropriate choice for cutting things. Cutting with a laser saves time and effort compared to utilizing various tools and equipment. 

Utilizing a suitable laser cutting machine and acceptable materials that can be cut using the laser machine you pick takes less time and effort than other methods.

A standard laser cutting machine can quickly cut through lightweight and less robust materials such as paper, cardboard, foam, and other similar substances. 

Consequently, the things that require the utilization of these materials can now be hacked and utilized without the requirement for the use of massive and heavy equipment – all that is required is the assistance of a laser cutting machine

When it comes to cutting foam board with a laser, one of the most dependable and well-suited alternatives for companies and industries that produce foam and the products made from foam is the utilization of lasers.

In addition, there are many products created using foam in today’s world, so having a solution that can cut foam is undoubtedly a relief.

Does the Laser Have the Capability of Cutting Foam?

Laser Foam Cutting

It is crucial to determine whether or not foam can be cut using a laser machine before investing in a machine specifically designed for cutting foam. Some materials cannot be cut using a laser cutter, even though this method makes it simpler to cut products that are lighter and not as durable. In addition to cutting an item, it is essential to check that the product is not damaged or cracked in any other locations before beginning the cutting process. 

Therefore, although laser cutting may appear to be a simpler and more convenient alternative for cutting, it may require additional concentration to prevent the object from being destroyed.

When you want to cut foam material with a laser, you should be aware that not all types of foam are ideal for laser cutting. Instead, the foam created with polyethylene, polyester, or polyurethane is a better option for laser cutting because of its rigidity. 

After having these different kinds of foams cut using a laser cutter, the result gives you the ability to use the foam in various contexts.

Is it Possible to Use A Laser Cutter On Polyurethane Foam?

Polyurethane Foam

The physical process of eliminating material happens when the material is sliced with a laser. One has the material removed from the top to the bottom, while the other has only a portion of the top removed until it reaches a particular depth.

A very high percentage of the CO2 laser’s energy may be absorbed by polyurethane foam. When high-intensity laser light is absorbed by polyurethane foam, the material immediately begins to transform that light energy into heat at the molecular level. 

The thermoset nature of this particular form of polyurethane foam makes it susceptible to the quick chemical disintegration that can result from sufficient heat. The laser will cause the portion of the substance that it affects to vaporize.

Can You Use a Laser to Cut Different Types of Foam?

Laser engraving and laser cutting are excellent applications for foams comprised of polyurethane, polythene, or polyester. Foam, EVA foam polyurethane, foam board, and other foam varieties are examples of common types of foam materials.

Is EVA Foam Suitable for Being Cut with A Laser?

EVA Foam Suitable

EVA is an acronym that stands for ethylene-vinyl acetate, and it is a copolymer. EVA foam has very low water absorption, high shock absorption, and a soft texture.

EVA foam is frequently utilized for a wide variety of container and casing applications, and it is also adaptable for use in a variety of accessory applications. This foam, which is both soft and hard, maybe readily sliced with a laser.

How Can EVA Foam Be Cut with a Laser Cutter?

Before we begin laser cutting EVA foam, we need to ensure that our health and safety are protected. Even though EVA foam is not a hazardous material, anyone who uses a laser cutter needs to have some protective equipment on hands, such as safety glasses and a laser fume extractor, among other things.

Cutting EVA foam with a laser is a straightforward process, but there are a few things you should know before you begin. If you set the operating speed too fast, it will not cut the material, and if you set it too slow, it will burn the material. The thickness of your EVA foam sheet will determine the number of pathways available to you.

Using a Laser to Cut Through the Foam:

When successfully cutting the foam using a laser cutter and obtaining the necessary foam material, what should you do? Have you given any consideration to how you will put the foam cut with the laser? Don’t be concerned. Imagine that you are just starting a new business that involves cutting foam, but you don’t have many ideas on how you may use the laser to cut foam in various ways.

The Advantages of Using a Laser to Cut Foam:

Advantages of Using a Laser to Cut Foam

There is a significant difference between going to the market to buy an apple and investing in laser cutting equipment. Laser cutting machines are an expensive piece of machinery because they are now acquainted and regularly employed in several industries today. 

This is because laser cutting machines can simplify and improve the quality of cutting and engraving operations.

But because there are so many different costs, some of which may be out of your price range if you don’t establish a budget, you need to be very certain about why you want to buy the machine in the first place. 

On top of that, you can’t spend a substantial amount of money on a laser foam cutting process and then just put it away in the storage room, can you? Therefore, before you go ahead and make the purchase, let’s take a look at some of the most important advantages that are owning a laser foam engraving machine offers in terms of promoting your company and gaining more clients.

Least Damages:

You are working with a highly developed and cutting-edge piece of equipment whenever you use a laser foam cutting machine. This implies that the cutting or engraving procedure does not alter the product’s overall appearance due to the cutting or engraving technology utilized in the laser cutter. 

On the other hand, the traditional tools and equipment used to cut things like foam frequently end up causing more damage to the product as a whole since they come into touch with other product regions when cutting it. 

On the other hand, laser cutters do not make physical contact with the material being cut and instead focus their attention solely on the region that the user has designated as the target. Consequently, there is a reduced risk that the item will be harmed when a laser engraver is utilized.

Versatile Performance:

The adaptability of the equipment is one of the most significant advantages offered by utilizing a laser cutter to cut foams. Processing foam is a task that benefits greatly from applying this cutting-edge technology

This enables interaction with various shapes and patterns etched into the foam while virtually using all foam material. Therefore, there is no need to place any restrictions on the varieties of foam that may be cut with a laser cutter while working with foam

Time Saving:

One further significant advantage of using a laser to cut foam is the opportunity to economize significant amounts of time. When you’re in charge of operating a company, you have to find time to do many different things. But cutting foam to create a variety of goods might take a significant amount of time if you use traditional methods. 

On the other hand, laser cutting machines have relatively few moving components, making them a technology that requires very little upkeep. Therefore, while utilizing a laser cutter, you can either cut or engrave without any additional hassle. 

Therefore, employing a laser cutter makes it possible to cut the foam rapidly while also reducing the time needed to move between different features.

Requires Less Manual Labor:

When working with foam, using a laser engraver eliminates the need for manual labor. You will only be able to complete the operation with a minimum effort if you opt to have the design engraved on the foam or cut out using a cutting machine. 

The remaining steps of the procedure for a laser engraver are carried out automatically, which helps reduce costs associated with labor. Therefore, regardless of the size of the company that you manage, using a laser engraver may help you save money on additional labor costs.

Frequently Asked Questions:

What is the most effective tool for cutting through EVA foam?

The blade may be stropped using a butcher’s steel, another useful tool for maintaining its sharpness. Utilizing a hot knife tool with a temperature adjustment dial is another alternative. Additionally, the cutting edge will be lovely and smooth as it goes through.

Is it safe to use a laser cutter on foam core?

Because this material does not readily absorb the 1.06-micron fiber laser’s wavelength, it is not advised for usage with this material.

How do you make the edges of EVA foam smoother?

Sanding is the solution to your question in a nutshell. To get a smooth finish on the edges of your EVA Foam, you may either use sandpaper with an extremely fine grid or a rotary tool equipped with a stone bit or a sanding drum. Both of these options are available to you. If you run a Heat Gun or Blowtorch over the area that has been sanded, you will be able to get rid of any lingering fuzzy particles of foam.


We hope you enjoyed our post about laser cutting Eva foam. With this expertise, we know that you will be able to produce a broad selection of unique components to help you build your business.

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