99. Electrical tape 7. Hot Wire Foam Cutter (This is the exact one that Will uses) The Hot Wire Foam Cutter has adjustable collars allowing for clean, accurate cuts in foam. The parts should be pretty easy to find. Thread the other end of the string though the opposite leg's hole. The throat of the Hot Wire Foam Cutter is 4.5" wide by 5.5" deep. My name is Will and if you have questions I salvaged mine, but you could use another extention cord if you like. if you do it backwards, you wont have any adjustment. Square up the frame and tie off the string. Instead of the ingenious tensioning method described, I used a guitar tuner, which I can tighten when the wire heats up and loosen after using. I should have used the 11V (it had 11, 24 and 44V) tap and varied that or just use the proper transformer. With this easy hot-wire foam cutter, you can reuse this leftover EPS foam to create treasures from trash! A hot wire foam cutter is a must have tool for all arts and crafts enthusiasts. Reply I finally got some 22 gauge nichrome wire. In this tutorial I give you the complete plans for making all the wood parts of this project. Add … It can be kind of floppy when plucked but should be pretty much straight when at rest. Without this step your contraption will easily wobble into a parallelogram. NiChrome Wire (NiCr) is the optimal cutting wire choice for Foam cutting equipment for a variety of reasons, but particularly because it is resistant against corrosion and oxidation at very high temperature. Make a sort of a big H shape out of your pieces by bolting them loosely together with the machine screws. I have a youtube channel with over 800 Project Videos! I have used professional ones and they have a pre measured nichrome wire with loops on the ends. Your guitar string should have a sort of a bead (for lack of the proper name) on one end. on Introduction, Instead of guitar string, use Constantan. The voltage will only go so high, but I do have control over the amperage. So, the length of the loop when taut should be about the same as the distance between the bolts. so that I can get more accurate right angle cuts by guiding the styrofoam through it. they are cheap and light . Reply Try playing with the dimmer switch setting to get the best cut. It should slice smoothly into the foam. The large table with 15 11/32" x 11" (390 x 280 mm) and working surface of Alu Cobond compound ensures smooth and easy movement of the work piece. You get like 16 strands in there of some pretty small gauge wire. 1 year ago When you pass electricity through a wire it gets hot. 9 years ago And nichrome wire is very reliable and very predictable. This will mean the wire quickly cools and won’t get further than leaving a line in the surface. Initial Settings: You have to provide the following inputs to the software before a cutting session: An LED indicates operation and helps prevent burnt fingers (the cutting wire heats to the maximum temperature in less than 1 second). $79.98. Variable 1-24V worked great but it died after about 5 minutes on 12V. The uses for computer power supplies are nearly endless. 4.0 out of 5 stars 54. Hold the bow by the wood stick and touch the wire to the foam where you wish to cut. contribute projects or ideas you can contact me. You can see what the final hook-up looks like close-up in the photos for step 7. Wrench to match the nuts (I didn't have my SAE wrenches handy so I used a 9mm) 11. on Introduction. Hot wire cutting machine is for cutting Styrofoam and similar insulating materials. 7. I have not read the other comments yet but I know the guitar string will limit the length of wing blank you can cut. Hi, Thanks for visiting my website. The template for this project with all the plans and dimensions is right here: Hot Wire Foam Cutter Plans. I know this is some old commentary, but I wanted to correct some mis-information. Paypal makes it very easy and safe. And in this next picture the handle has been removed and you can use it as a hand-held cutter. With your fire extinguisher handy and your body away from the device, plug it in. The corners join up nicely. $39.99 $ 39. Some people set up their cutters in sort of a bandsaw configuration, so that small pieces can be manipulated against a table for precise cutting. I can confirm that a hf (smps) lighting psu works well . You should of course use the wire nuts that came with the dimmer switch (esp on the 120V connections) and/or tape to ensure that no bare wires touch each other, or you, or your pet. Because this post helped me, I'm adding photos of my setup.I didn't use a dimmer, rather a transformer that has 8 volt settings. I used stainless wire from a 1/16 cable strand bought for .17/foot at Home depot. The large format models provide longer and wider cutting areas which can provide customers with the capability of producing large foam shapes in a single piece. Maybe that's what's going on - a 44 watt light bulb would be plenty hot. If you turn up the dimmer too fast, your wire may burn out before you realize that it's even hot. The unit comes with 2 LCD displays, providing accurate readout for the voltage and current values. Make A Hot Wire Foam Cutter:-The hot wire foam cutter is a tool used to cut polystyrene foam and similar types of materials. Cut a flat plywood board to 70cm x 45cm ( 27.5″ x 17.7″ ). $7.98. or would like to The arm is a semi rigid spring steel 90 degree bend that bends down to accept the wire and rebounds to apply tension. At 15 inches it is 1.1 ohms cold. Core77er gmay3able recently shared a clever creation of his with our fellow readers much to our delight: a DIY hot wire foam cutter table.. And it has pretty good strength. Screwdriver 5. For cutting white styrofoam I have reduced the current to .80 amps. Has any one tryed useing a hf lighting p.s.u with a dimmer ? So it will last and it is very useful for a hot wire foam cutter. In the second picture we have applied a current to it. This project was created on 11/30/2020 and last updated a month ago. We can consequently lower the voltage and current for it. Run a strip of packaging tape down each corner. The concept is very simple. And I show you how to wire it up. Now Nichrome has a resistivity ranging from 1.10 × 10−6 Ωm to 1.50 × 10−6 Ωm.and a very high boiling point (~1400 °C). If you drop the box, the transformer will shatter it. Note:The correct temperature, being dependent on material and thickness, is learnt from experience. Hot Wire Foam Cutter Power Supply Design. single 40AWG strand broke under stress so we upped it to 3 strands. 1 settings being 0v and the rest starting from 9v working up to 30v.15v worked best with a 70cm gap or length of nichrome wire. This box was made from 4 cd cases and some packaging tape. Even a 6V lantern battery straight wired to cutter generated enough heat to slice the foam. Foam Cutter Pen2pcs,100-240V/15W 10CM Electric Foam Cutting Machine Pen Tools Kit/Foam Craft Hot Wire Cutter DIY Crafts/Polystyrene Cutting Engraving Pen with Power Adaptor 4.0 out of 5 … Gareth Branwyn. on Introduction. The printed grid and protractor assist with division and cutting. Don't tighten the nuts down yet, just get 'em on there kinda loose. Cut the unmounted side of the split to about one foot. The hot wire foam cutter described in this article was designed to work well for most of your projects. Plug the appliance cord into a live wall outlet. I used a bamboo skewer. We supply hot wire foam sculpting tools, Crafter’s Hot Knives, Pro Hot Knives, and an Industrial Hot Knife. This is an easy hot wire foam cutter project and it is also quite unique in that it is two tools in one. This photo is your wiring diagram. So, we can use this wire tautly across a gap and put electricity through it and we have a nice hot wire foam cutter. The foam Engraving tool is perfect for detailing your foam sculpture. Here's a fun project for the long holiday weekend via our discussion boards! Now you can tighten down the nut. Hot Wire Foam Cutter, 30W 25cm Electric Hot Wire Cutter Foam Polystyrene Heat 9.8 9.3 9.9 2: Hot Wire Hand Held Foam Cutter - For Styrofoam, Polystyrene and Foam | 9.3 8.8 9.4 3: They also rectified the AC to DC to make it a lot safer for the end user as I was touching the wire more than once. A couple of cable ties or twist ties 6. Our polystyrene EPS, XPS cutting systems and equipment are sold in Europe and in many countries throughout the World, from Asia, Africa to North (South) America and Australia.. We ship foam cutters, hot knife cutters and hot wire CNC foam cutting machines All over over the World. also there is usually lots of mica heat board in there too , good to act as insulated guides for the wire as well, http://www.hhhh.org/~joeboy/resources/hotwire_foam_cutter/hotwire_foam_cutter.html, http://members.fortunecity.co.uk/slmohr/rcinterest2.htm, http://www.vatsaas.org/rtv/construction/hotwirecutter.aspx. To avoid the emission of toxic fumes, we recommend using the Hot Wire Foam Cutter and the Bow and Guide on Woodland Scenics foam products only. 4 #10-24 x 1.25" machine screws with nuts, $1 at Home Depot 4. Now I like this idea. Reply 5 years ago In the first picture here we see nichrome wire hooked up to a power supply. This photo is just to show what connects where. Strip the insulation off the last inch of one end of one wire of the cord. This is the power supply that I purchased and use for this project: Tekpower Variable DC Power Supply, 0-18 Volts, @ 0-3 Amps. Don't bother without the Nichrome. Be careful not to electrocute yourself or start a fire. This makes it quick to disconnect the wire and run it through a closed hole in the workpiece to make interior cuts. Steel wire broke broke right away. To make a tensioner for the hot wire I would buy a machine head from the guitar shop/ music store. on Introduction. I deleted a comment or reply I made about the resistance measurement I took on the ''E'' of my guitar. NiChrome wire has high tensile strength and a high melting point. Foam cutting works because the foam shrinks where the wire cuts it (the bubbles in the foam collapse), so even though the melted foam re-hardens, a gap is left where the wire passed through. Once you are sure everything's all set, grab the frame and try laying the wire on some scrap styrofoam. 8 years ago Repeat with another string for the other side, but when you tie off the string at the top of the leg this time, make sure you have some tension. Small wood saw 3. This is the nichrome wire that I use in this project. A Styrofoam cutter basically works by heating a wire using Ohm's Laws, where the heat is equal to I2R where I is the current flowing throw the wire and R is the resistance. There are a lot of alternatives listed or linked below for the frame, the transformer, the wire, the enclosure, and the heat control. With several different models available to choose from depending on your needs, our sure to have a foam wire cutter in our range that matches with your foam cutting project needs. For sale is a brand new, professional DC regulated power supply from Mastech, Model number HY1803D. foam cutter styrofoam Hot wire workbench. Reply You will have an understanding of the wire and how it works so you can adjust things as you want them. Pluck the wire and listen for a musical tone. A type of wire called NiChrome is perfect for this. I think around $1? Multitester (you don't NEED one but it's a good safety check) 10. I will try this and report back . You might be able to do the whole project with just a knife, a drill and some tape, but it would be better to have the following: 1. If the wire is not super tight at this point, don't worry. 2 wooden yard sticks from the Home Depot paint department, $.97 each 3. Parts required to build a Hot Wire CNC Foam Cutter Stepper Motors – these drive the towers where the hot wire is attached Control Board 4 axis – sends signals to the stepper motors to move a certain amount and in which direction. designed exactly for tensioning guitar strings it makes tightening the hot wire quick and easy. Turn the dimmer all the way down (counterclockwise). Put the nut on, but don't tighten it down at all. https://en.wikipedia.org/wiki/Constantan. Bend the bare wire of the extension cord (the part you just strippeed) into a U shape, and hook it around the screw between the two washers. the unit I have spare can suppy 9.2A @ 11.4vac and is dimmerble .They also have thermal protection . SLOWLY (like 5 degrees per second) turn the dimmer up (clockwise) til the wire starts to quietly hum. Save the plug and outlets for future projects, if you like. Even if you could get the wire that would stay strong enough at the appropriate temperature, the lead would act as a big heat sink and wick heat away fromwhere you want your cut. Make a loop by feeding the other end through this bead. I'd expect the same effect would apply in foam wire cutter wire. I needed the information you provided before making a proper comment. I think this kind of box might have some other uses. Jared - one of the tricks I have learned is when you make your templates, number the edges from 1 thru ten from the leading edge to the trailing edge. Building the Ultimate Hot Wire Foam Cutting Table. Once you are happy with the tension, slide the ruler or dowel down so that the yardstick keeps it from unwinding (see the photo). 4.0 out of 5 stars 54. See this page for an example:http://www.hhhh.org/~joeboy/resources/hotwire_foam_cutter/hotwire_foam_cutter.htmlThe enclosure for the transformer and dimmer needs to be more rugged, and it should incorporate a fuse, maybe a power indicator, and maybe a modular connector to facilitate attachment of larger or smaller cutters.Instructables user Moofie suggested rigidifying the connection to one of the legs, perhaps simply by using a second bolt where the yardsticks overlap, to eliminate the need for the criss-cross strings. The black two conductor wire on the left goes to the wall plug, and the brown one on the right goes to the hot wire. Can this be attained by using this process. Aug 30, 2016 - Plywood Hot Wire Foam Cutter: I recently started working on my own tutorial blog, makerguides.com. Get it as soon as Mon, Jan 11. Keep the loop pretty close to the nut or there will be too much twisting force on the leg when the wire is tensioned. 1. You can read about all kinds of things people do to power their hot wire foam cutter including things like running 110V through a light bulb in series with the foam cutter, battery chargers, dimmer switches, Variacs, "wall warts", batteries, and so on. So 24" of Nichrome from an old dryer hooked up to a 12v car battery made 50 cuts through 12" thick styrofoam before it even broke once. About 12 feet of strong, low-stretch string. I really want to make a different box for this project, or buy a project box at Radio Shack. The wire heats up and cools down within a second or two. Cut one of the yardsticks in half. The template with all the plans and dimensions is right here. Set the rig up somewhere where it won't catch the house on fire or melt the carpet if something is wired wrong, or if the wire overheats and breaks. Then again, It comes with three quick-change tips. Nibble or cut a hole for the dimmer switch and tape it in. The device consists of a thin metal wire, often made of stainless steel or nichrome, or a thicker wire preformed into a desired … The large format Xydroid contour cutting machine has all of the features included with the standard format hot wire cutter and more. No. Optimum profiles are cut at lower temperatures and while applying less cutting force. There shouldn't be yet. Didn't need to make precise cuts. And there are a few different ways you can power up the hot wire so I will show you how I did it and I will give you some alternatives. Wrap the end of the wire around the other terminal screw and twist it off. Click here to donate $1 - Every little bit helps Will to keep making great tutorials and projects. If the wire doesn't hum or heat up by the time the dimmer is halfway up, turn the dimmer all the … See the second photo. Careful not to twist too much or you'll break the wire or the frame. It might help to use pliers to keep good tension, but be careful not to pull too hard and break the wire. Probably a much lighter gauge would work fine as well, but may not be as strong. About $10 at Home Depot. Cuts styrofoam for surfboards, model plane wings, sculpture, model train or tabletop wargame terrain, 3D sign letters, mold models for lost foam casting, etc.5/17/2007, Important note! Please be sure to read the comments that other users have left below. :). To hook up the other end of the wire, pull the frame legs towards each other so your string tensioning loop on the other end is taut. See the photos. 10. The body is mainly made of plastic using 3D printed parts. I went that route and connected one of the 12V outputs of the power supply to a length of nichrome wire salvaged from an electric heater. It has a hot wire cutting setting but I am finding it difficult to manipulate. How to Build a USB Hot Wire CNC Foam Cutter – Free eBook. The white foam is styrofoam and it is very easy to cut. This worked, but the guitar string broke after about 30 seconds. on Introduction. There's a LOT of good info there. It worked quite well. Is the hotwire still whole? This will extend the life of the hot wire. Take a piece of string about 6 feet long and thread it through each hole on the other ends of the legs, as shown. Even if you could get the wire to cut, the lead would simply fuse together again once the wire had moved on. A tensioner for the dimmer switch and tape it in, its strong quality and allows for a hot cutter. 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