Thanks! If someone comes up with a better way to size and cut them, let us know.

Funny- selling these as an aftermarket item crossed my mind, too. I suppose if there are CAD drawings of all the variations of manufacture/model so that they could be cut on demand for many different vehicles, that might work.

I learned from another project that cutting PVC and similar materials using a laser isn't really feasible. It tends to destroy the laser for some reason. So they would need to be hand cut or shaped using some sort of die. Major machinery.

Maybe 3D printed? Can that even be done with flexible, foam-like materials?

Edit:

Actually, I guess this is just like a dress pattern. If the correct dimensions could be printed on large format paper, a set of those for any vehicle could be easily sold for people to trace on their own foam.

hmmm...

Toyota 4Runner (2009) 3D Model - 3D CAD Browser