FFM2012,
In the "idea" category, here's a method of cutting sheet foam for RC airplanes with a reciprocating needle. Currently, it handles up to 1/2" sheet foam material but, being DIY, the stroke length can be altered somewhat. I'm not sure how it handles open-cell foam or thickness greater than 1/2"... but it's cheap, easy to build, and might be worth checking out with some 1/2" open-cell material to see how it cuts. -- David
http://www.cnczone.com/forums/cnc-wi...cnc-forum.html