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To enter the weekly challenge for using wire, I decided to write up my very first hotwire project. I did this about 15 years ago, and realized now how useful it can be to those who would like to get their feet wet in the hotwire arena. I have since made more substantial, electrically powered hotwire machines (see: http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/), but this was the first, was very inexpensive, and was a starting point for me. Maybe it can be for you as well. Total cost can be way less than $20.
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At work one day, I was challenged by a statement from a co-worker: "You need to find a way to recycle some of this styrofoam." (We received shipments that needed refrigeration, and they all came in dense styrofoam containers). Being a self proclaimed artist, I thought it would be fun and challenging to be able to reuse said boxes and containers. As chance would have it, I stopped by a Michaels and was guided to the floral section where there was this "Wonder Cutter." (See: http://www.amazon.com/FloraCraft-Styrofoam-Accessories-Styro-Cutter/dp/B000XALM54/ref=sr_1_2?ie=UTF8&qid=1323063429&sr=8-2). It was a device that was used to cut or slice floral foam, and it did that by heating a wire that could be used in the cutting of the foam. Just what I needed. Please be aware that the device shown on Amazon is the latest version of the tool I used. It is different in the switching, and case. It should be "hackable" though, but check it out first.
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Another way to make one of this is to use a metal guitar string (the skinny "E") and an old power supply for a router/modem/house-hold item or computer PSU.
4 volts/500 milliamps should do...