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Gaterfoam letters and designs

John Larson

New Member
What tool is generally used to cut those nice 1" thick dimensional letters I see on the grocery store walls, and other indoor displays? I thought it was a computer driven router table but the ones I looked at the other day had very tight interior corners - which indicates that even an 1/8" router bit cutter wasn't used.

I used my laser engraver to cut a 3/16" thick gaterfoam letter the other day but I melted the foam.

Any ideas?


New Member
Gatorfoam? I just use regular hand tools. Jigsaw and scroll saw. If you jigsaw it, you'll need to take sandpaper to it after its cut. Love this board, but hate the foam chunks. You keep finding this crap days after.