Tools/HotWireFoamCutter

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RLab has a Proxxon Thermocut 650 hand-held hot wire cutter.

The user manual for this can be found here.

A hot wire foam cutter is a device which utilizes the heat dissipated by a nichrome wire to melt foam evenly and in straight lines. Its applications include:

Cutting padding for packaging and containers.
Creating armatures for mache, laminate, and fiberglass.
Cutting insulation to the correct size.
Creating positives for metal casting or for silicone.
Creating bulking for boffer weapons and other latex-on-foam objects.
Sculpting foam for decorative use.
Sculpting landscapes for model building.
Cutting walls and structural aspects of architectural models.
Making foam planes.
Making prototypes.

This tool is accompanied by a range of jigs and hand tools (some electric, some not).

Jigs[edit]

Jig	Functionality	Usage
Built in mitre	For adjusting angles on the Y-Z plane.
Y Fence	A fence that sets the maximum distance the foam can move in the Y axis.	.
Mitre Fence	A fence that sets the maximum distance the foam can move in the X axis, and an angle at which it can move on the X-Y plane.
Circle Jig	Guides the cutting of perfect circles and cones

Electric Hand Tools[edit]

The hot wire foam cutter has a plug on it that allows the use of electric nicrome hand tools.

Tool	Functionality	Usage
Bendable loop tool	For cutting exact or random profiles into foam.	When the tool is fully cooled, bend the wire to the desired shape.
Taut cutting tool	For cutting off chunks straight in one axis.	Ensure wire is tight.
Cheese cutter	For cutting large chunks that are straight in one axis,	Wind wire to desired length, clip to the circuit.
Pen tool	For more delicate designs such as writing and embelishments.	Simply hold as you would a pen.

Non Electric Hand Tools[edit]

The tools in this list are nothing to do with the machine, but are used in foam crafting and so I've placed them on this wiki page. Feel free to move if I've made a mistake.

Tool	Functionality	Usage
Wire brushes	These are used for cutting away material, particularly for rounding off or roughing.	Select the size, length, density, and hardness based on what you want to do. For larger curves, use larger brushes (duh), for smoother curves use a higher density with a softer bristle.
Nail brushes	These are exclusively roughing tools and cannot be used to make precise curves. Can only really be used on crumbly foams.	NA
Vinyl carving knives	As the name implies, these were originally invented for carving vinyl. As a result, they can only really be used on foams that aren't crumbly, but are excellent for defining more precise detail.	To all intents and purposes, the shape of the tool is the shape of the cut it makes: a V shaped knife will cut a V shaped slot, a U shaped knife will cut a U shaped slot, etc.
Soft sanding block	Basically a sponge on a stick. Great for smoothing curves.	Attach appropriate grit sandpaper, by turning screw on back.
Knife	Used for quickly cutting away chunks	NA

Types of foam[edit]

Below is a rough guide for foams, their uses, and at what temperature you must cut them:

Foam	Use	Cutting temperature / °C	Number on dial
Polystyrene	Padding Model landscapes Metal casting positives	210 - 249	Example
Polyurethane	Insulation Model landscapes Props and decor Forms for mache / fiberglass	50 - 60	Example
Polyethylene	Padding	105 - 115	Example
Crosslinked Polyethylene	Metal casting positives Boffer weapons / armor
Latex foam	Upholstery Padding	120 - 180
Plastic coated foam board	Architectural models Model airplanes
Polyisocyanurate	Insulation Model landscapes Forms for mache / fiberglass	200
L200	Boffer weapons / armor
Ethylene-Vinyl Acetate	Padding Boffer weapons / armor	71 - 72

DO NOT CUT USING HEAT:

ANY cellulose foam
Expanded PVC
Paper or PVC coated foam board

Also be wary of any foil coated foam. You may wish to cut away the foil prior to cutting.