Form cutting is a process that is done using a special piece of equipment referred to as a hot-wire foam cutter. The machine cuts materials such as polystyrene foam. The cutter has many components that include a thin and a taut metal wire that gets heated through electrical resistance in order to be able to cut through material. The temperature of foam cutting wires usually reaches 200 degrees Celsius or more depending on the model of the machine.
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.
These days, CNC capabilities have been introduced into foam cutting. This increases the ability and accuracy to cut very intricate shapes. Nevertheless, accuracy of CNC machines may be affected by factors like stepper motors, backlash of the drive systems, and rigidity of races used for supporting effectors. End effectors are normally used to hold tensioned wires.
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.
These days, CNC capabilities have been introduced into foam cutting. This increases the ability and accuracy to cut very intricate shapes. Nevertheless, accuracy of CNC machines may be affected by factors like stepper motors, backlash of the drive systems, and rigidity of races used for supporting effectors. End effectors are normally used to hold tensioned wires.
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