Introduction: Cordless Lost Foam Cast Cutting Tool - USB Rechargeable

About: After being laid off in 2009, I got rid of my car to save money. The difficult transition from a car to a bicycle led me to start Solarcycle and design USB chargers that keep smart phones alive.

This Instructable is for how to make a Cordless Lost Foam Cast Cutting Tool.

Please click below to visit our Kickstarter project page ro pre-order a production model!


QTY Description

1 2" Long piece of Kanthal 28 ga wire

1 Roll of .07" DIA coated clothesline wire

1 RCA to screw terminal adapter


1 Needle nose pliers with cutter

1 Small phillips screwdriver

1 Solderdoodle Pro 2.0

Step 1:

Cut about 3 inches of the clothesline wire and strip both ends, one end .25" and the other end .5".

Put a .5" 90 degree bend on the end with the .25" stripped.

Depending on the width of the foam cutter you want, put a 1.5" (or less) 90 degree bend on the other stripped end. (You can also bend the wire in any shape you want to fit your needs)

Insert the .25" stripped ends of the wires in to the RCA to screw terminal adapter. Tighten the screw terminals with the phillips screw driver very tight and make sure the wires are flat along the same plane.

Take a strand of Kanthal wire and tie it between the .5" stripped ends. Making a groove with the wire cutter for the Kanthal wire helps hold the tie in place.

Attach to the Solderdoodle, turn the Solderdoodle on, and start lost foam cast cutting! (Instructions on how to build the Solderdoodle can be found here

For experts, you can connect the RCA connector to a 2.5 Vto 5V power supply with up to 1.4 Amps of current.

Once you create your foam shapes, cut them, put them in sand and pour the molten metal in. The foam will melt and be replaced with the metal! You can search how to lost foam cast in any way that fits your style.

Happy foam cutting!

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