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Cut polystyrene foam with an electric kitchen knife. Use an electric kitchen knife, such as a carving knife or a fish fillet knife, to create clean cuts in Styrofoam. Place the electric knife on the foam along the desired cutting line.
Carve the shape in the negative form so you can use the foam shape directly as a mold. Brush on a layer of clear sealer over the mold. Allow to dry for at least four hours. You may wish to apply several layers. Do not use an oil-based sealer as it may melt the polystyrene.