CNC Foam Cutters are capable of cutting out some pretty cool shapes that would otherwise be extremely difficult to do. They do this by pulling a heated metal wire though a block of foam.

Just cut the foam and plywood to your desired shape and size, glue the foam to the plywood, cover with your fabric, pull ...

they devised a method of making controlled curved cuts through foam by using a 1-mm thick deformable rod rather than a limp and floppy wire for the cutting tool. The robot has seven degrees of ...