Tiny Foam Hole Saw Cutter

I started to design a hole cutter for foam but then I found out that niki_m beat me to it. I needed a smaller version so after some trial and error I got something that works well.

It basically a cutter printed in vas mode (Cura: Spiralize Outer Contour) with a plug for added strength in the chuck. The hole in the plug lets the air escape and it can also be used to push out the center core. I find it easier to pull out the core with a wood screw.

I only include diameter 15mm cutter for 10mm thick foam. I have tested dia 8 to dia 20 with good results.

I guess that you can make Nerf gun ammo with a longer version.

Fusion and step files included.

Usage
Put a hard surface on the backside.

Set your cordless drill to a high-speed setting and press the hole saw into the foam lightly BEFORE starting the drill.

Once you start the drill, wait a few seconds for the initial cut to be made then slowly move it through the material. Move the drill up and down a few times to smoo