How To Make 3D Foam Fighter Jets

Make cool 3D puzzles, or a squadron of elastic powered fighter jets crafted with foam from the dollar-store.

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Free Foam Fighter Jet Template Only:

How To Make The Styro-Slicer:

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This idea was partially inspired by Sonic Dad’s Foam Plate F-22 project (

WARNING: Styrofoam crafting involves high temperature cutting wires which can burn skin, and release small quantities of toxic gasses from the styrofoam itself. Metal casting should only be attempted under adult supervision, by those skilled in the process, and who understand the risks. Have fun, but always think ahead, and remember that any project you try is at YOUR OWN RISK.

Project History & More Info:

For the foreseeable future, this is the very last of the foam cutting projects, and marks the end of the Styro-Slicer series.

After playing around making styrofoam handguns and styrofoam swords I was anxious to create another fun project that could be use with the Styro-Slicer, and immediately thought of those wooden 3D puzzles that lock together, like dinosaurs, and motorcycles.

I searched around the internet a bit, and came across some wooden 3D fighter jet puzzles I thought looked cool, and the more I studied them the more convinced I was that I needed to make a 3D puzzle jet.

Looking through pictures of fighter jets on google, I fell in love with the SU-27 Russian fighter jet and liked it’s style above any else.

Now that I knew which jet I wanted to make, I did a search on eBay just to see if there were any wooden versions of the SU-27 in puzzle form, and there were! So I ordered one for $17 .. ouch!

When the puzzle came, I studied it in great detail, then spent an 8 hour day re-creating it in photoshop.

I printed the templates onto paper, and cut out the foam pieces, only to find out that the width of the foam was larger than the wood, so it didn’t work, and needed to be totally re-designed.

I spent countless hours at my computer re-sizing, recreating, reprinting, recutting, and retesting multiple variations of my model. After 5 prototypes, I finally got a version that worked with the foam-board!

For finishing touches I added color and texture to the templates to make them look cool, then went ahead and filmed the making of the 3D model.

But as cool as the 3D puzzles were, I really wanted to make something that could fly, and I went back to the internet for inspiration.

Searching foam fighter jets on the internet eventually led me to a Sonic Dad project, “How to Make an F-22 Raptor Model Airplane from Foam Plates – SonicDad Project #34” (

This idea of a launch-able fighter jet was awesome, and quickly inspired me to make a new version of my template that could slot together and form a “Fling Fighter” similar to Ritchie’s. And with a little tweaking and a few extra features, they worked amazingly well!

I love the Fling Fighter version because it’s quick and easy to make, and even my 6 yr old boy was excited to make them on his own. They don’t require any gluing, and they’re surprisingly durable.

We had fun flinging them around the house, and I was so amazed by how straight we could get them to fly, and how far they would go.

In conclusion, I’m really excited to present these Fling Fighter Jets as another awesome project you can make with the “Styro-Slicer” and hope you enjoy making them as well. If you don’t have foam, try making them with cardboard, and let me know how it goes.