Form cutting is a procedure performed by use of special equipment known as hot-wire foam cutters. This machine is utilized to cut materials like polystyrene foam. Many components including a thin taut metal wire are included in the cutter. The metal wire is usually heated via electrical resistance so that it can cut through material. Usually, the temperature of foam cutting wires reaches over 200 degrees Celsius depending on the type of machine in use.
Although in most cases the wire is made from nichrome or stainless steel, it can also be made from a variety of other materials. This wire may be pre-formed into any kind of desirable shape. The wire is normally hot in the sense that it does not require to have contact with the material so as to cut it. Normally, the material gets vaporized before coming in contact with the tensioned wire.
Tensioning of the wire can be done using a bow or a frame that has springs. Many people tend to favor a single strand of stainless steel wire over nichrome wire if diameters range from 0.008 inches to 0.020 inches. This diameter is suitable for frame-tensioned cutters. Commercially, a nickel-based alloy wire Rene 41 is often preferred. This nickel-based alloy is preferred because is maintains its tensile strength at cutting temperatures.
The machine is appropriate for cutting of a wide variety of materials. Particularly, it is preferable for cutting through all forms of thermofusible expanded foams. Normally, these are materials which need low temperatures in order to melt. Polymethacrylimide, extruded polystyrene, expanded polystyrene blocks, custom materials, and flexible expanded polypropylene foams are examples of material that can be cut using the equipment.
Several types of these cutters exist today. Some of them include computer numerically controlled cutters, push through slicers, template-guided manual tables, simple manual cutting tables, handheld devices and preformed wires. Usually, preformed wires are attached with handles and they must be guided manually by the operator for them to cut. They find use in making free shapes. Also, handheld cutters operate in a similar way where they are manually guided to cut freehand shapes by the operator.
Hot wire foam cutting tables usually have a horizontal table that is used to secure the foam work piece in place. The wire, which may be horizontal or vertical then cuts through the work piece secured on the table. Hobbyists usually use vertical wires to cut small, but complex shapes like letters. Vertical tables can be utilized to cut prismatic members only.
Horizontal tables find most use in the construction and packaging industries. The table contains tracks on either side, which are used to hold the wire. The tracks enable the wire to be moved with a great level of precision. The tracks allow both upward and downward motion. Angular cuts can also be produced by horizontal tables.
Today, CNC capabilities have been integrated into foam cutting. This gives even more capability to cut extremely sophisticated shapes with great accuracy. However, factors like stiffness of races used for supporting end effectors, stepper motors, and backlash of drive systems can affect accuracy. Usually, tensioned wires are held by the end effectors.
Although in most cases the wire is made from nichrome or stainless steel, it can also be made from a variety of other materials. This wire may be pre-formed into any kind of desirable shape. The wire is normally hot in the sense that it does not require to have contact with the material so as to cut it. Normally, the material gets vaporized before coming in contact with the tensioned wire.
Tensioning of the wire can be done using a bow or a frame that has springs. Many people tend to favor a single strand of stainless steel wire over nichrome wire if diameters range from 0.008 inches to 0.020 inches. This diameter is suitable for frame-tensioned cutters. Commercially, a nickel-based alloy wire Rene 41 is often preferred. This nickel-based alloy is preferred because is maintains its tensile strength at cutting temperatures.
The machine is appropriate for cutting of a wide variety of materials. Particularly, it is preferable for cutting through all forms of thermofusible expanded foams. Normally, these are materials which need low temperatures in order to melt. Polymethacrylimide, extruded polystyrene, expanded polystyrene blocks, custom materials, and flexible expanded polypropylene foams are examples of material that can be cut using the equipment.
Several types of these cutters exist today. Some of them include computer numerically controlled cutters, push through slicers, template-guided manual tables, simple manual cutting tables, handheld devices and preformed wires. Usually, preformed wires are attached with handles and they must be guided manually by the operator for them to cut. They find use in making free shapes. Also, handheld cutters operate in a similar way where they are manually guided to cut freehand shapes by the operator.
Hot wire foam cutting tables usually have a horizontal table that is used to secure the foam work piece in place. The wire, which may be horizontal or vertical then cuts through the work piece secured on the table. Hobbyists usually use vertical wires to cut small, but complex shapes like letters. Vertical tables can be utilized to cut prismatic members only.
Horizontal tables find most use in the construction and packaging industries. The table contains tracks on either side, which are used to hold the wire. The tracks enable the wire to be moved with a great level of precision. The tracks allow both upward and downward motion. Angular cuts can also be produced by horizontal tables.
Today, CNC capabilities have been integrated into foam cutting. This gives even more capability to cut extremely sophisticated shapes with great accuracy. However, factors like stiffness of races used for supporting end effectors, stepper motors, and backlash of drive systems can affect accuracy. Usually, tensioned wires are held by the end effectors.
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