In the world of CNC, a "crack" often refers to a break in the continuous cutting path. If your foam pieces are coming out with jagged edges or unintended gaps, it’s usually due to:

During the cutting process, if the foam block isn't secured, vibrations can lead to hairline fractures along the formers.

If the heat settings are too high, the wire melts more foam than planned (the kerf). This can make the foam sections so thin that they crack under their own weight.