I do a lot of work with styrofoam, and like to think of new ways to handle the foam easily and efficiently. To that end, I wanted to make a sculpting tool to add details to various styrofoam projects. Since I had several hotwire machines, the next step was to make a cutter that could be hand held, used like a pencil or paint brush, not get too hot to hold, and be able to shape the material as wanted. Hence the tool presented here.
Step 1: Materials Needed
To make my cutter, I assembled wire of various types, some electrical wire of course, and a piece of nichrome wire to use as the cutter itself. I needed a dowel to be the "pencil" or wand itself, and to this I used small screws to make "posts" where the supply wires could be attached. Miscellaneous hand tools are needed such as wire cutter, screw driver, needle nose pliers, etc. Also, some alligator clips are used to connect wires for testing and use.