Styrofoam is perfectly acceptable for diffusion, as long as it is not an soft, open cell type. Density is not really an issues since these only work on high frequencies to begin with.
If you are interested in making your own a free tool called "QRDude" is really useful for making custom 1d and 2d panels.
You can find much higher quality 1 1/4" square white pine at Home Depot. A little more expensive, but worth it for looks. It is a good idea to glue the edges of the bars as you insert them.