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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.

Foam Cutter 120x80 final.dxf
Download

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: