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Tools/HotWireFoamCutter: Difference between revisions
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{{toolsneedingattention}}
RLab has a Proxxon Thermocut 650 hand-held hot wire cutter.
The user manual for this can be found [[media:Thermocut_650_manual.pdf|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).
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! 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 ||
|}
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| 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.
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| Knife || Used for quickly cutting away chunks || NA
|}
== Types of foam ==
Below is a rough guide for foams, their uses, and at what temperature you must cut them:
{| class="wikitable"
|-
! 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.
[[Category:Tools]]
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