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
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