Tools/HotWireFoamCutter: Difference between revisions
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RLab has a Proxxon Thermocut 650 hand-held hot wire cutter. |
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The user manual for this can be found [[media:Thermocut_650_manual.pdf|here.]] |
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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: |
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: |
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* Cutting padding for packaging and containers. |
* Cutting padding for packaging and containers. |
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* Creating armatures for mache and fiberglass. |
* Creating armatures for mache, laminate, and fiberglass. |
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* Cutting insulation to the correct size. |
* Cutting insulation to the correct size. |
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* Creating positives for metal casting. |
* Creating positives for metal casting or for silicone. |
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* Creating bulking for boffer weapons and other latex-on-foam objects. |
* Creating bulking for boffer weapons and other latex-on-foam objects. |
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* Sculpting foam for decorative use. |
* Sculpting foam for decorative use. |
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* Sculpting landscapes for model building. |
* Sculpting landscapes for model building. |
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* Cutting walls and structural aspects of architectural models. |
* Cutting walls and structural aspects of architectural models. |
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* Making foam planes. |
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* Making prototypes. |
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This tool is accompanied by a range of jigs and hand tools (some electric, some not). |
This tool is accompanied by a range of jigs and hand tools (some electric, some not). |
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! Foam !! Use !! Cutting temperature !! Number on dial |
! Foam !! Use !! Cutting temperature / °C !! Number on dial |
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| Polystyrene || |
| Polystyrene || |
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* Padding |
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* Model landscapes |
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* Metal casting positives |
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|| 210 - 249|| Example |
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| Polyurethane || |
| Polyurethane || |
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* Insulation |
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* Model landscapes |
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* Props and decor |
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* Forms for mache / fiberglass |
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|| 50 - 60 || Example |
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| Polyethylene |
| Polyethylene || |
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* Padding |
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|| 105 - 115 || Example |
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| Crosslinked Polyethylene || |
| Crosslinked Polyethylene || |
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* Metal casting positives |
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* Boffer weapons / armor |
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| Latex foam |
| Latex foam || |
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* Upholstery |
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* Padding |
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|| 120 - 180 || |
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| Plastic coated foam board |
| Plastic coated foam board || |
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* Architectural models |
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* Model airplanes |
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| Polyisocyanurate |
| Polyisocyanurate || |
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* Insulation |
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* Model landscapes |
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* Forms for mache / fiberglass |
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|| 200 || |
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|L200 || |
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* Boffer weapons / armor |
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| Ethylene-Vinyl Acetate || |
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*Padding |
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*Boffer weapons / armor |
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|| 71 - 72 || |
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DO NOT CUT: |
DO NOT CUT USING HEAT: |
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* ANY cellulose foam |
* ANY cellulose foam |
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* Expanded PVC |
* Expanded PVC |
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* Paper coated foam board |
* Paper or PVC coated foam board |
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Also be wary of any foil coated foam. You may wish to cut away the foil prior to cutting. |
Also be wary of any foil coated foam. You may wish to cut away the foil prior to cutting. |
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[[Category:Tools]] |
Latest revision as of 15:51, 9 November 2023
This page has been noted as requiring attention to bring it up to the basic standard as per the guidance
Please remove this tag once this page has been improved that standard
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).
<Information about dimensions of particular one which is to be made>
Jigs[edit]
Jig | Functionality | Usage |
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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 |
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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 |
|
210 - 249 | Example |
Polyurethane |
|
50 - 60 | Example |
Polyethylene |
|
105 - 115 | Example |
Crosslinked Polyethylene |
|
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Latex foam |
|
120 - 180 | |
Plastic coated foam board |
|
||
Polyisocyanurate |
|
200 | |
L200 |
|
||
Ethylene-Vinyl Acetate |
|
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.