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I imagine that "warning" is just to protect themselves in this overly sue-happy society we live in. If the stuff really was all that dangerous, you can be darn sure there would be warnings printed all over the product itself. Obviously, the foam creates dust when you carve or cut it with a knife or other such tool, and you need to avoid breating in those fine particles. I wear a respirator if I'm doing any serious carving to Extruded Polystyrene, and generally use a "hot knife" to do any detail work (which produces some fumes, but no dust). Folks have been using this stuff for years--myself included--and I've yet to hear of anyone suffering any significant harm. The carved foam gets covered by a coat of paint or plaster in nearly all cases, or, in the way I use it, gets covered by a layer of Sculptamold. Besides, you can't live forever, and we all know by now that virtually everything we touch or consume these days is bad for us in one way or another. Just listen to or watch any daily news program and you'll find the latest items added to the list. Regarding availability: Depends on what part of the country you live in. Those in warmer climates may have a hard time finding the stuff since it's sold as an insulating material. Those in colder climates (or more seasonal climates) will generally find it at most any well-stocked home supply store. I had no problem finding the stuff when I lived in the Milwaukee area. Have had a more difficult time finding it here in Virginia, although my local Home Depot began carrying it about a year or so ago.
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