Pro Foam Cutting Machine

2,671

57

14

Introduction: Pro Foam Cutting Machine

About: Welcome to Motivatips Channel, we are all about helping you. Science, Technology & Engineering videos and more :) I hope you like these videos, and if you have any suggestions or opinions please contact u…

Thanks for watching


There are many projects to make using a Foam, but working with foam using Multi-Purpose Craft Knife is hard and inaccurate, so I decided to make a hot wire foam cutting machine.

In this Foam Cutter, you can make an unlimited number of shapes in many sizes and get professional work.

I will talk about this project in 5 steps, also I have a video if you liked this video, make sure to subscribe for more!

Step 1: Circuit

I tried many ways to power the nichrome wire and test many circuits, but the safest way to power and load the nichrome wire is using DC motor speed controller 5A circuit.

I used a 12v dc adapter up to 18v with this circuit.

Materials:

  • 1 x 555 Timer Integrated

  • 1 x IRF540N Power Mosfet

  • 2 x 1N4007 Diode

  • 1 x FR157 Diode

  • 2 x 0.1uf Capacitor

  • 1 x 100uF Capacitor

  • 1 x 50K Potentiometer

  • 1 x 10K Resistor

  • 1 x 1K Resistor

  • 1 x 5mm LED (Red)

  • 1 x 5 * 5 PCB Board

  • 2 x PCB Terminal Blocks

You need Soldering iron, wires, and cutter.

I tested the circuit using a dc motor and everything very well.

Step 2: How to Get Nichrome Wire

There are many ways to get Nichrome wire, you can buy it as a new wire or got it from any soldering iron.

For me, I got it from my broken soldering iron and it is very good.

Step 3: Body

I made the design using Autodesk Autocad to cut it using laser CNC, I used wood board 2.5mm thickness.

At this point, it is up to you to use any material to make the body.

You can adjust the angle of cutting from the arm in an easy and accurate way.

Materials:

  • 1 x 120*80 cm wood board 2.5mm thickness
  • Laser CNC
  • Superglue
  • Rubber bands
  • 4mm Screws

Finally, I got a powerful and very Geometric body.

Step 4: Assembling All Parts Together

Here we are getting to finish this project.

I used a 5mm iron rail to wrap the nichrome wire, so I can adjust the length of the wire if you changed the angle of cutting also the nichrome wire extend when heating.

I connected the wires to the circuit using PCB terminal blocks, also added dimension stickers to the body to cut accurately and without a ruler, you can engrave the dimension on the body using laser CNC, but I missed it.

Materials:

  • Switch
  • PortLED
  • Female dc jack
  • 5mm Iron rail
  • Hot glue
  • Wires
  • Dimension stickers

Step 5: Cutting

I am really surprised what this cutter can do, I am happy with the result it is very accurate and professional work.

“Thanks for watching and reading”

Build a Tool Contest

Participated in the
Build a Tool Contest

Be the First to Share

    Recommendations

    • Space Contest

      Space Contest
    • Fashion Challenge

      Fashion Challenge
    • Halloween Contest

      Halloween Contest

    14 Comments

    0
    johnflux
    johnflux

    11 months ago

    Can you provide the autocad file please? Ideally as svg, but anything would be awesome. Thank you!

    0
    AyhamAS
    AyhamAS

    Reply 11 months ago

    Of course, sorry I missed this point to add the laser cut file.
    I edited again my Instructables, you can download it from step 3: body.
    Thanks.

    0
    txblueslady
    txblueslady

    11 months ago

    what a great idea!

    0
    AyhamAS
    AyhamAS

    Reply 11 months ago

    Thanks

    0
    wannabemadsci
    wannabemadsci

    11 months ago

    Very nice hot wire cutter. The video provides a pretty good visual explanation, but the written portion could use more explanation. Had to watch the video to understand the capabilities. Lots of flexibility to do different things - especially like the 45 degree option.
    Do you really need an adjustment on the heating of the wire? Could you just leave it at a preset amount of heating?
    Thanks for sharing. Hopefully it will introduce many people to how useful a hot wire cutter can be.
    I used my own one to make some giant puzzle pieces (see https://www.instructables.com/Glowing-Giant-Puzzle... - expand to see all photos.).

    0
    AyhamAS
    AyhamAS

    Reply 11 months ago

    Thank you for your kind comment, I saw your giant puzzle pieces it is an amazing and new idea for me.
    According to your question, I had seen many videos and did many experiments for a hot wire foam cutter, so I noticed that every kind of foam and every thickness need different degrees of heating, and I realized the low heat gives you more soft and accurate cut.
    Also, I did a new DIY 3d letter using this foam cutter (see https://www.instructables.com/How-to-Make-Your-Own-Letters-Using-Styrofoam-and-W/).

    0
    druševljan
    druševljan

    Question 12 months ago

    Maybe you could explain a bit more why is motor controller necessary and why it is the best solution

    0
    AyhamAS
    AyhamAS

    Answer 12 months ago

    Thank you for your question
    On my experience and expertise in this project, I found the motor controller the best solution for me, and you can power the hot wire directly from a DC volt adapter, but you can not change the hotness of the wire by a fixed dc volt unless using a variable DC power supply.
    I prefered to make something independent for this cutter and able to control the hotness of the wire to get a perfect cut, also the circuit able to load up to 5A, so I can work for a long time without damaging the MOSFET transistor.
    Please don't hesitate to tell me if I missed something, thanks

    0
    druševljan
    druševljan

    Reply 12 months ago

    Well, if I knew what is the best way, I would not be reading instructable how to make one :) . Anyway, I do not remember seeing any foam cutter using the dc motor controller so I asked why you choose to use it. I guess some form of PWM control (like in light dimmer) might also work, but what is better I do not know.

    0
    AyhamAS
    AyhamAS

    Reply 12 months ago

    I understood you, also I do not know the better one, but I saw some makers used a light dimmer.

    0
    AnandM54
    AnandM54

    12 months ago

    Wow... Great..... Great instructables..100% planned work.. But u could explain some more.. overall Brilliant...👏👏👏

    0
    AyhamAS
    AyhamAS

    Reply 12 months ago

    Thank you very much, I really appreciate your amazing words, and I will always do my best in the next projects.

    0
    Iluvananimals
    Iluvananimals

    12 months ago

    It looks like you put a lot of effort in to it

    0
    AyhamAS
    AyhamAS

    Reply 12 months ago

    Thanks for supporting me.
    Yes, it took more than a week, and most parts took time are the circuit and the design.