Foam block bore cutting apparatus

A bore making apparatus for a foam block comprising:

• a frame;
• a plurality of tubular, hollow bore forming members, each bore forming member having an open top end and an open bottom end and having a predetermined wall thickness, each said bore forming member having a defined cross-sectional shape, which is substantially uniform from the top end to the bottom end, said bore forming members being aligned in an array and attached to said frame, with each member spaced a pre-determined distance from an adjacent one of said members;
• each bore forming member further comprising a resistive heating element having a predetermined heat output, attached to the bottom end, wherein said resistive heating element corresponds in cross-sectional shape and wall thickness to said bore forming member for forming a channel within said foam block corresponding to the cross-sectional shape and wall thickness of said tubular bore forming member;
• foam supporting means for rigidly holding said foam block, slidably mounted within said frame;
• means for sliding said foam supporting means into said array of bore forming members at a predetermined rate corresponding to said predetermined heat output, such that a plurality of bores of uniform thickness and cross-section are substantially simultaneously formed within said foam block with cores of said bores being enclosed within said tubular bore forming members.