Tiny Foam Hole Saw Cutter

thingiverse

I started to design a hole cutter for foam but then I found out that niki_m beat me to it. I needed a smaller version so after some trial and error I got something that works well. It basically a cutter printed in vas mode (Cura: Spiralize Outer Contour) with a plug for added strength in the chuck. The hole in the plug lets the air escape and it can also be used to push out the center core. I find it easier to pull out the core with a wood screw. I only include diameter 15mm cutter for 10mm thick foam. I have tested dia 8 to dia 20 with good results. I guess that you can make Nerf gun ammo with a longer version. Fusion and step files included. <h1>Usage</h1> Put a hard surface on the backside. Set your cordless drill to a high-speed setting and press the hole saw into the foam lightly BEFORE starting the drill. Once you start the drill, wait a few seconds for the initial cut to be made then slowly move it through the material. Move the drill up and down a few times to smooth the surfaces. Update 2023-04-20: I did some more testing and high speed was actually better so niki_m was right. I updated the instruction.