I've been cutting lots of foamboard at the moment, Ive been using the 1mm downcut cutting tool available from Stoney-CNC with great success, an excellent finish. Make sure you have another piece of foamboard under the one you're cutting though so the tool cuts straight through into that not plywood at 20mm/sec!
Good points Rory, i should have clarified this in my piece!
Once I finish moving house (again) ill try to do some more professional photos, but as a reference, please see the attached picture of a FT22 plane myself and my girlfriend just built! cut completely by my s600 and any rough edges you may see is poor hot glue control *cough not me*
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Looks good. Did you ever have a problem with the cutter getting clogged up with the dust and ruining the foam? I have. The cutter must have heated the foam enough for it to melt onto the cutter and build up, expand and ruin the project. Anyone have any ideas to keep this from happening?