Introduction: Hot Wire Foam Cutter
How To Make Your Own Hot Wire Cutter
Step 1: Materials Required
1. Popsicle sticks
2. Old rectangular cardboard box
3. Old chopsticks
5. Spray Paint
7. Ice pick
8. Super Glue
9. Zip ties (100 mm)
1. Led green 5mm
3. Toggle Switch DPDT
4. Mini 2 Pin SPST Switch
5. Electrical tape
7. USB Led light
8. Nichrome wire 32 AWG
9. Some wire
10. Aligator clips x3
11. Broken Phone charger
12. Broken car charger
1. Soldering iron
2. Dremel or a drill
Step 2: Design
Step 3: Making Support for Wire
The lower part
To make it simple I have used popsicle sticks and a chopstick to make the support system.
First I took 3 popsicle sticks and cut the curved top and bottom of all the 3 sticks, then marked the centre of 2 sticks and glued the 3rd stick on the line (as shown in the diagram ).
The upper part
For this again take 3 sticks but this time cut the curved top of only 2 sticks. Drill 2 holes at the top and bottom of the 3rd stick make the second hole a bit bigger, also cut a piece of the stick as shown in the image. Now glue the parts as shown in the picture.
Step 4: Attaching the Support to the Box
Glue the support to the box and then insert the chopstick through the big hole and into the box and then add glue to the chopstick inside the box so that the chopstick sticks to the box and then tighten it with a zip tie.
I have spray painted mine white colour .
Step 5: Adding the Electronics
Make a hole in the box and attach the nichrome wire with the help of washer. Then attach the nichrome wire with the toggle switch as follows
- Pin 2
- Pin 3
Usb red wire
- Pin 5
- Pin 6
Usb red wire
Also, attach a 68-ohm resistor to the -ve of led
Use the picture for reference
Now for the light, we will use the same battery source and a broken car charger and a SPST switch
Attach the led light as given in the picture
Step 6: TRY IT
Attach the usb to a power bank or your laptop and its ready for use. we can cut thermacol or styrofoam using it.
Let me know how you used it. Comments Below !