How to cut foam rubber neatly?
How to cut memory foam cleanly? - Tool Talk
Ive never cut memory foam - but we produced assemblies for aircraft customers that included various foam inserts (almost like upholstery cushions). We had a Bosch A with several different lengths of knife blades for different thicknesses. It sort of works like an electric knife that uses 2 counter moving scalloped-edged blades to do the cutting. I was then a pricey tool and Im not sure that it is still made. I see on Amazon that there are alternatives:
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https://www.amazon.com/s?k=bosch+foam+rubber+cutter&gclid=EAIaIQobChMIlv7Gm-Pe_QIVi_7jBx3_xgQeEAAYAiAAEgJ85vD_BwE&hvadid=&hvdev=c&hvlocphy=&hvnetw=g&hvqmt=e&hvrand=&hvtargid=kwd-&hydadcr=_&tag=googhydr-20&ref=pd_sl_4l2xvt1bk1_e
The Hercules one looks much like the old Bosch - and was probably sourced from Harbor Freight - but is no longer available on their site.
The current Bosch model doesnt seem to be readily available this side of the pond - but can be ordered (very expensive for a 1 off project)
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You might also experiment with a much less expensive electric knife:
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4 Easy Ways to Cut Rubber Foam
Rubber foam is a strong, spongy material often used in mattresses and other items that need to be durable. Because of its unique consistency, it can be challenging to cut. Always outline planned cuts first, then choose a cutter according to the thickness of the foam. Utility knives are fine for very thin pieces, but switch to serrated knives for most pieces and a bandsaw or fabric cutting saw for the thickest ones. Slice through the foam at a slow and steady rate to ensure you project is a success.
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