GETTING YOUR IDEAS OUT OF YOUR HEAD AND INTO THE REAL WORLD.

Foam-Core Prototyping

Prototyping

It is necessary to be able to convey your ideas to others effectively.

A picture is worth a 1000 words . . .. . ., but a three-dimensional prototype is

most often needed. A prototype:

is inexpensive is quickly made (in comparison to the final product) represents the proposed product or device

Types of Prototypes

There are several types of prototypes: Concept drawings (simple sketches to get the ball

rolling) Virtual computer simulations (like Solid Edge) Mathematical models (MathCAD, MatLab and Excel) Clay models (often seen in the automotive industry) Foam-core (like the one you are about to make)

Some prototypes are fully functional, …… but many are just spatial representations.

Foam-Core

Foam-core (or Foam Board) is one material that can be used for quickly prototyping your ideas.

Foam-core is a composite material consisting of: An outer layer of card stock And inner layer of foam (like Styrofoam) And another layer of card stock

Tools for Working with Foam-Core

Only a few basic tools are needed for Foam-Core: Cutting mat (so you don’t cut up the table top!) Cutting knife (Exacto, or box cutter) with a sharp

blade Metal ruler (for measuring and making straight cuts) Pencil or a pen (for marking the cut lines) Tape (clear packing tape works well) Hot glue can be used also, but not required (low-

temperature!)

Getting Started with Foam-Core

Make sure you have a good, solid surface to work on and BE SURE TO USE THE CUTTING MAT!

Let’s start with just cutting a straight lineSince foam-core has three layers, it is usually

best to make three cuts: Cut through the top layer of card stock Cut through the layer of foam Cut through the bottom layer of card stock

If you try to cut through all three layers at once, you will end up with a jagged mess!

Cutting a Line

First, measure and mark the line. You may want to start at the 1” mark on your ruler, as

the scale on some rulers does not go all the way to the end.

Be sure your fingers are out of the way!Make the THREE cuts.

Measuring

from the 1”

mark.

Fingers out the cutting path.

With three cuts,

you get a really

nice edge!

Types of Corners

At some point you are going to want to join your foam-core pieces together – there are at least three types of corners that you can make: Overlapped Mitered Rabbeted

Overlapped RabbetedMitered

Overlap Corner

The overlap joint is the simplest corner to make.

Simply cut the two pieces and tape them together to create the corner.

It helps to lay the tape down (sticky side up) on your work surface and place the first piece of foam-core on top of the tape.

Miter Corner

Mitering a corner makes for a nice clean outside, as there is no break in the material.

Cut a V-shaped groove in the foam-core.The angle of the “V” determines the angle of

the resulting corner.

The V-

groove.

Angle the cutting knife to create the groove.

Rabbeted Corner

The rabbeted corner gives a nicer looking corner than the overlap, and is easier than making the mitered corner.

Cut through one layer of cardstock, and the foam-core, but not through the other layer of cardstock.

Only cut through two layers of the foam-core.

Cut at 90-degrees from your first cut to form the rabbet. A rabbet!