- 1). Lay the paper pattern for the object you want to make over a Styrofoam sheet or block. This should be a simple drawing of the overall shape you need the Styrofoam to have. You can tape the paper pattern in place, if necessary.
- 2). Apply a small amount of wax to a craft knife so that the knife will cut smoothly. Cut the Styrofoam along your paper pattern lines until you have a rough overall shape.
- 3). Remove the paper pattern from your Styrofoam piece. Refine the shape by carving around your cut edges again. If you would like a smoother line, you can use an electric, hot-wire Styrofoam cutter.
- 4). Add the texture you would like your Styrofoam piece to have. If you are making a prop, you may be looking for a rough or rock-like texture. Flake pieces of Styrofoam off the overall piece using tools like a wire brush, an ice scraper and a cheese grater.
- 5). Bend your Styrofoam piece if you require a curved shape for your project. Take a few wooden dowels or pieces of wood in the size curve you need, and fit the Styrofoam piece around them. Clamp the dowels together, sandwiching the Styrofoam between them.
- 6). Fill a plastic tub with water that is heated to 90 degrees Celsius. Immerse the clamped Styrofoam in the water. Do not touch the hot water with your hands.
- 7). Remove the Styrofoam from the water once it has cooled enough to touch. Remove the wooden dowels. Your Styrofoam piece will have formed to the shape of the dowels.
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