Using Foam(ed) Plastics

Appropriate PPE should always be worn when cutting, sanding, carving, gluing, spraying, or mixing foamed plastics.

Recommended PPE includes:

• Safety glasses or chemical splash goggles
• Chemical-resistant gloves
• Long sleeves and long pants
• Closed-toe shoes
• Face shield when appropriate
• NIOSH-approved respirator when producing dust or using products that release hazardous vapors

Ordinary dust masks do not protect against chemical vapors and should not be relied upon where respirators are required.

Ventilation

Cutting, sanding, shaping, spraying, or mixing foamed plastics can generate hazardous dust, vapors, or fumes. Because CalArts does not provide dedicated local exhaust ventilation for these operations, fabrication that creates significant dust or vapors should be performed outdoors whenever practical or in another location approved by Production Services.

Never work with spray foams or large quantities of chemical foams in enclosed, poorly ventilated spaces.

General Safe Work Practices

Always follow these safety guidelines:

• Read the manufacturer’s Safety Data Sheet (SDS) before using any foam product.
• Allow adhesives, coatings, and A/B foams to fully cure before sanding, carving, or machining.
• Keep work areas clean and free of foam dust and debris.
• Regularly vacuum or sweep accumulated dust using methods that minimize airborne particles.
• Never eat, drink, or smoke while working with foam materials.
• Wash hands thoroughly after handling foam products.
• Keep ignition sources separated from fabrication areas.
• Never expose foam products to incompatible chemicals or solvents unless approved by the manufacturer.
• Be aware of others working nearby when using sharp carving tools or power equipment.

Sculpting and Cutting Foam

Many fabrication techniques use knives, rasps, saws, hot-wire cutters, rotary tools, sanders, or other equipment. When shaping foam:

• Use sharp tools carefully and cut away from your body whenever possible.
• Secure workpieces before cutting.
• Maintain awareness of people working nearby.
• Wear appropriate eye protection at all times.
• Minimize dust generation whenever possible.
• Keep the work area clean by removing dust and scrap material frequently.
• Exercise extreme caution when using hot-wire cutters, which present both burn and fire hazards. Never leave a hot-wire cutter unattended while energized.

Storage and Disposal

Store foamed plastics in cool, dry locations away from direct sunlight, heaters, pilot lights, electrical equipment, and other ignition sources. Do not allow large quantities of foam scrap to accumulate inside studios or shops. Uncured A/B foam products may continue generating heat after mixing and should be disposed of only after they have completely cured according to the manufacturer’s instructions.

Dispose of foam waste, chemical containers, and unused products in accordance with CalArts procedures and all applicable local, state, and federal regulations. Never burn foam materials to dispose of them. If you are unsure whether a foam product or fabrication process is appropriate for your production, consult Production Services before beginning work.

This version is considerably cleaner, removes outdated or redundant OSHA language, updates the terminology (including XPS foam and NIOSH respirators), and better reflects current entertainment industry fabrication practices while remaining accessible for students.