Interesting concept Martin. Will be waiting for results from you on this one. If you are still punching out foam circles, you can get great "bumblebee" popper bodies by gluing up the circles into a cylinder and shaping it by sanding. With all the sheet foam colors available, you can keep busy all winter.
Both concepts are worth pursuing. I thought about the tapering effect as well. But I just purchased the half inch punch and will have to keep it at that for now... Research grant funding available? ;-)
I used to use the outside tube part of aluminum wall anchors (Molly bolts) as cutters. Zip out the bolt and cut off the bottom, bevel the lower edge to make a cutting edge. You can grind them on a bench grinder or chuck them into a drill and bevel with a file. The anchors come in many sizes and if you sharpen them well, they cut smoothly through standard craft store foam sheets. Just push down on the foam and twist. I never had great luck just trying to "punch" through the foam myself.
Yeah, nine bucks isn't cheap but the tool will last and last at any rate. The craft stores like Michael's and AC Moore used to carry precut foam circles in a big plastic tub. All diameters and colors. Can't find it around here any longer. Now it's all kinds of shapes for scrap booking and rainy day "keep the kids busy" . The bumblebee style popper bodies I made with these got so popular with my friends that I used up the whole supply. Imagine my annoyance when I couldn't find the tub any longer.
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