EPP foam has some special requirements for fabrication.

For example, polypropylene is a material known for its resistance to adhesives that are water based, such as yellow wood glues. Cutting EPP takes some skill as well.

Here are some basic tips. For additional detail, click here

Glue and Adhesives
The best material for gluing EPP is a polyurethane glue, available in most hardware stores under various brand names. CA glue, or Cyanoacrylate, also easily available under different brand names, is also appropriate for bonding EPP to itself or other compatible material for fabrication purposes. However, with CA glue, you must use an additional component known as an accelerator.

There are adhesives known as Room Temperature Vulcanizing (RTV) adhesives that are suitable for EPP. An Elmer's Glue product known as ProBond is suitable for use with EPP, but be careful. ProBond expands as it cures, and can ruin a smooth surface if this fact is not anticipated.

Finally, two-part epoxies work well with EPP.

Be extremely careful to follow all manufacturer's safety warnings. Work with glues only in well ventilated areas. Do not use them around children or pets. Do not leave open containers exposed to children or pets.

Cutting and Forming
A band saw is very useful when working with EPP. A table saw is not recommended because of its high speed, and because EPP has a tendency to grab the blade under certain conditions. A band saw works at lower speeds, has finer teeth, and provides greater control when properly used.

In addition a hot wire cutter works well with EPP to cut contours and to help create a finished shape. There are many details found on our links.

Visit our links for resources on Hot Wire Cutters.

TIP: Filament packaging tape can be wrapped around an EPP shape, such as a wing, for example, to help create a smoothed surface as well as add some lightweight reinforcement, helping balance the tension / compression performance characteristics to the EPP. Some builders prefer to butt the tape without overlap to produce a smoother surface on the foam. Others prefer to overlap the tape by 2mm to 4mm to produce a bit of additional strength. Either method works well.