Make a CNC Hot Wire Foam Cutter from parts available at your local hardware store like HomeDepot . This machine can be used to cut wings for RC planes, surfboards, crown molding, packaging foam and lots more
The original design was built in order to cut RC wings (even tapered wings - where one side is different then the other side)
Polystyrene (EPS and XPS) will cut using a hot wire - other foams - like polyurethane should only be cut with a blade or saw.
When cutting, be careful !!! - wire will get hot, and some people may be allergic to the EPS fumes - always work in a well ventilated area.
Step 1: Over View
Most parts can be found in your local hardware store, like Home Depot..
The first prototype was made out of wood, but didn't look "professional" enough, so I decided to go with a more robust design made of steel.
The design can be modified to almost any size. Keep in mind that for longer travel you will need a longer lead screw.
The problem with a long lead screw is that because it its own mass, it will "wobble" in higher speeds.
One way to overcome this problem is to move to a larger diameter lead screw.
Another way is to move to a chain or belt driven design. Belt driven machines are usually 8' and longer but require the use of micro-stepping. An example of a machine larger then 8 foot would be a surfboard foam cutter.
Some surfboards are up to 12 feet in length, the only way to cut these boards would be a belt driven or chain driven mechanism
I will try to cover this topic in the future with a sample machine and pictures...
We started out building a machine to cut wing cores, but soon after we discovered a huge interest in the machine for other industries - like moldings, architectures, surfboards, Logos, props, packaging Willow Sills, Casings, Wainscoat , Fascia, Crown, Parapets, Wallcaps, Pediments, Quatrefoils, Columns