A method for fabricating a solid foam article from a solid foam blank includes the steps of forming a pilot hole in the solid foam blank; positioning a chisel in the pilot hole, the chisel having a cutting portion and a shaft; and directing the cutting portion into the pilot hole in a reciprocating motion to remove solid foam material surrounding the pilot hole. A system for forming articles from solid foam blanks and a heat exchange device are also disclosed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
 This invention was made with government support under DE-ACO5-000R22725 awarded by the United States Department of Energy. The Government has certain rights in the invention.