Tools/HotWireFoamCutter
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 and fiberglass.
- Cutting insulation to the correct size
- Creating positives for metal casting
- Creating bulking for boffer weapons and other latex-on-foam objects
- Sculpting foam for decorative use
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
| Jig | Functionality | Usage |
|---|---|---|
| Built in mitre | For adjusting angles on the Y-Z plane. | Unscrew the knob on the arm of the foam cutter, and turn to the desired angle, rescrew. |
| Y Fence | A fence that sets the maximum distance the foam can move in the Y axis. | Unscrew the knobs on either end of the fence, slide to the desired position, rescrew. |
| 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. | Unscrew the knob on the protractor and adjust to the appropriate angle, rescrew. Then unscrew the two knobs on the rail and adjust the fence distance, rescrew. |
| Circle Jig | Guides the cutting of perfect circles and cones | Unscrew jig and slide to the desired distance from the wire. Mark rotation center on foam. Uncover pin and place into marked center. |
Electric Hand Tools
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
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. | 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
| Foam | Use | Temperature | Number on dial |
|---|---|---|---|
| Example | Example | Example | Example |
| Example | Example | Example | Example |
| Example | Example | Example | Example |