At one time I was using a lot of foam core sheets in my art practice building sculptures and installations. After learning that foam core is actually very toxic, I decided to conduct research into a sustainable alternative. I reached out to the director of a local USDA research group who generously shared a bio-based recipe with me. I then experimented with the raw ingredients, comparing different starches, paper pulps, and drying methods. The process involved using large amounts of pure alcohol to evaporate the moisture quickly, allowing the foam structure to dry without collapsing. Results varied, but overall I was able to make a respectable homemade version, something I'd call, cottage-foam-core.
