Question: If the first layer of foam and the second layer of foam (pattern) are pressed in to the recessed wooden mold where is it actually cut. I have watched this several times and I just can not get it clear in my mind.

I know what you mean Billy.  I have a really hard time wrapping my head around this one. The foam is is cut in a "straight" line at the top of the white foam but because there is more pushed into the the bottom wooden template it comes out in the shape of the bottom template combined with the top foam one.

That's a very cool video, I have heard of processes like this before but never seen it done.

There is an easier way to do this, something I've been experimenting with lately. Instead of using the pressure-cutting machine make a standard mold of whatever you want to make and cast the puppet part in cold foam; a two-part liquid that when mixed together expands and turns in to foam. It works very well; you can even cast armatures inside the foam (although that is a little trickier).

I can post photos of heads cast in cold foam if anyone is interested.

That's a very cool video, I have heard of processes like this before but never seen it done.

There is an easier way to do this, something I've been experimenting with lately. Instead of using the pressure-cutting machine make a standard mold of whatever you want to make and cast the puppet part in cold foam; a two-part liquid that when mixed together expands and turns in to foam. It works very well; you can even cast armatures inside the foam (although that is a little trickier).

I can post photos of heads cast in cold foam if anyone is interested.

Yes Andrew photos would be welcomed.