how to make a hot knife to cut styrofoam

also there is usually lots of mica heat board in there too , good to act as insulated guides for the wire as well, http://www.hhhh.org/~joeboy/resources/hotwire_foam_cutter/hotwire_foam_cutter.html, http://members.fortunecity.co.uk/slmohr/rcinterest2.htm, http://www.vatsaas.org/rtv/construction/hotwirecutter.aspx, How to Make Charcuterie Boards Using Clear Acrylic Templates. Sometimes, other guides will recommend you to take a hot wire cutter or an electric knife as added materials. has a step-by-step power controller to change the temperature of the blade and an LED indicator to show the degree of temperature change. Save the plug and outlets for future projects, if you like. Now I like this idea. https://www.facebook.com/makewithrex, and Subscribe us on Youtube https://www.youtube.com/prajjwalnag. The uses for computer power supplies are nearly endless. Probably a much lighter gauge would work fine as well, but may not be as strong. 4.2 out of 5 stars 30. Use cable ties, twist ties or string to keep the wire close to the frame so it won't get in the way when you're using the tool. Careful not to twist too much or you'll break the wire or the frame. 3 Tools In 1: Cut or Engrave Foam Complete Tool Set. Someone asked a questions earlier if you could you use a hot knife to shape neoprene and I would like to know if you can cut achieve a clean straight cut on Cross-Linked Polyethylene (Closed cell) using a hot knife tool if you use a guide. There's no such thing as an eye hook. A kitchen knife or a pocket knife can work well if it is sharp enough and if you have a grindstone or file to keep them sharp as you cut. The switch is on the handle. This box was made from 4 cd cases and some packaging tape. 4 years ago. I use a hot knife to cut the Styrofoam cement forms in basements for installing the electrical circuits. I salvaged mine, but you could use another extention cord if you like. Wide packaging tape 8. on Introduction. The 5-1/2 in. You could use something like a notebook power supply or probably the best bet is a variable voltage bench power supply. In each half, drill a hole in the middle and one about 1/2 inch from each end. 1 year ago. Take a moment to look over your creation and make sure all the wiring seems to make sense. An inside cut involves the removal of some of the styrofoam, but still having a solid outer piece. Now we're going to attach the wires that carry the 25V current to the cutting wire. I vaguely remember that light bulb resistance goes up by around a factor of 10 when it heats up. This 130 watt, heavy-duty hot knife cuts foam, EIFS, ICF, nylon rope, webbing, synthetic fabric, and plastics. Cuts styrofoam for surfboards, model plane wings, sculpture, model train or tabletop wargame terrain, 3D sign letters, mold models for lost foam casting, etc.5/17/2007, Important note! What I've done is to rip the styrofoam on a table saw. Have I mentioned that you should use a different design for your enclosure? 6. Get it as soon as Thu, Dec 10. Check em out. EIFS stucco hot knife Styrofoam cutter can cut not only foam but also plaster. All you need is either a utility knife or an electric saw to make clean cuts. The hot knife uses a slightly flexible hot shaft. One effective way to cut styrofoam is by using a hot blade knife. The wire under the effect of current, heat and cut easily and cleanly styrofoam, much much better than with a knife or a cutter, particularly for large pieces (> 5 cm thick). Starting the the end you just hooked up, pull the two conductors of the cord apart so that it's split for about 3 1/2 feet. Reattach the wire to the tool. This makes it quick to disconnect the wire and run it through a closed hole in the workpiece to make interior cuts. Hot Wire Foam Cutter Small Electric Styrofoam Polystyrene Craft DIY Hand Model Foam Cutting Tools 110V / 220V. The hot wire foam cutter is a tool used to cut polystyrene foam and similar types of materials. Now use this to quickly burn the styrofoam balls in half. You can see what the final hook-up looks like close-up in the photos for step 7. Steel wire broke broke right away. Utilize a hot wire cutter. We first start by cutting a PVC pipe, I had a 2 feet foot long one so I needed to cut into the following length. Using hot glue, paste the sticks on both the battery terminal. Cut polystyrene foam with an electric kitchen knife. blade on this hot knife quickly heats to 975° F to make fast, clean cuts in foam and plastic materials. Optional: 4 regular-thickness CD cases. A kitchen knife or a pocket knife can work well if it is sharp enough and if you have a grindstone or file to keep them sharp as you cut. I want to chime in as I had been a sculptor who has worked on some really huge Hollywood feature film productions sculpting massive sculptures for feature films as well as sculpting huge movie sets like rockwork for movies such as Pirates of the Caribbean for Disney and Planet of the Apes (Tim Burton's film) and many other films and television shows. Use an electric kitchen knife, such as a carving knife or a fish fillet knife, to create clean cuts in Styrofoam. The hot knife comes with a depth adjusting sled to make repeat cuts or long cuts at a precise depth. Nibbler 9. You get like 16 strands in there of some pretty small gauge wire. HI trickyThe power supply unit I have been using is basically a 12v halogen lighting transformer , these use high frequency (hf) switching to drive a high frequency transformer . Source(s): I'm an electrician. Now it was time to prepare the end cap, the end cap will be holding the spring which will stretch the nichrome wire. Use a waxed serrated knife, saw, floral knife or other craft knife to cut Styrofoam sheets and shapes. 130W power Always suit up and wear a disposable protective suit and cover your head/hair and wear disposable gloves when working with Styrofoam (EPS foam). The 5-1/2 in. The knife also has a switch like the bow cutter. Nibble or cut a hole for the dimmer switch and tape it in. Instead of the ingenious tensioning method described, I used a guitar tuner, which I can tighten when the wire heats up and loosen after using. Reply So, the length of the loop when taut should be about the same as the distance between the bolts. Buy the High-frequency ,switching type of transformer is NOT compatible with messing with the input voltage. About 7% of these are Knife. The melting point of lead is 330 degrees celcius. Do NOT heat cut foam in a closed environment. A wide variety of styrofoam hot knife cutter options are available to you, such as blade change style, handle material, and blade material. When the piece is loose, remove it. on Introduction, Instead of guitar string, use Constantan. Screwdriver 5. Plug the charger into the outlet. Slowly advance the dimmer switch until the wire becomes hot enough to melt the foam. At the same time, it should be sharp enough to be able to cut through the foam without much effort. The parts should be pretty easy to find. Now it was time to assemble them. 3 years ago. By Eric Limer. Lastly, I added some rubber feet so that this won't scratch the table when used on it. Are the lights still on? Draw the knife's blade over a plain candle to wax it thoroughly and then cut Styrofoam with long, sawlike motions. Those are generally not useful for cutting wings or slicing chunks off larger pieces. This helps prevent snags and tears. You'll see what I'm talking about here if you look at the photo. They also rectified the AC to DC to make it a lot safer for the end user as I was touching the wire more than once. If it sounds like "fwubababa" it needs more tension. In the photo, the box has been turned on it's side. Reply A 25 volt, 2 amp transformer, $10.49 from Radio Shack. Run a strip of packaging tape down each corner. The foam cutter can cut, BTW guys if you like this project and want to get updates on what's cooking in the workshop follow us on Facebook. 5 years ago on Introduction. (Build your own with these instructions.) Plug the appliance cord into a live wall outlet. You can use your multimeter to see if there's any current between the terminals. Place the electric knife on the foam along the desired cutting line. Even a 6V lantern battery straight wired to cutter generated enough heat to slice the foam. First, cut off each end of your 12 foot extension cord. Mine is 18"×18". Now it was time to add power to wire so that it can cut like butter. FREE Shipping by Amazon. Just a point of accuracy; it's called a screw eye. Sometimes, other guides will recommend you to take a hot wire cutter or an electric knife as added materials. You need room between the washers so you can put your wire in there. The PVC Table Screwand End Cap was actually 3D printed as I was not getting in the local market so I designed my own in Fusion 360. Reply I mounted an eye hook then to end cap and fixed it with a nut . Spread hot glue along the edges of the styrofoam board. It will be slow and tedious but if you do it right it wont be messy. has a step-by-step power controller to change the temperature of the blade and an LED indicator to show the degree of temperature change. With this pistol-style tool, you can cut at variable angles to get the exact details you are looking for in your craft. I would say you could cause a fire, and the wire might break. Now it was time to add the main thing, the NiChrome wire.I had got this Nichrome wire by salvaging it from Hair drier. Make a loop by feeding the other end through this bead. The answer is a hot foam cutter, which uses a heated wire to slice through the foam. If you are only doing two or three projects with this foam, then it's probably not a problem, but if you work with it every day as I did, then take every precaution. Im not sure how long the 25v transformer will last but it is cheap enough to give a try. You can always add more if it seems too floppy when you try to make your cuts. Your guitar string should have a sort of a bead (for lack of the proper name) on one end. About 12 feet of strong, low-stretch string. Then using 3 1/4 inch Screw I have attached the mount to the melamine. CDN$ 69.69 CDN$ 69. Place the electric knife on the foam along the desired cutting line. 11. I cut about 60 "Coors Light" cursive letter signs for a contract with this rig and never burned a wire. I used 200 lb dacron kite line. Once you are sure everything's all set, grab the frame and try laying the wire on some scrap styrofoam. Connect the boards to make an open box containing a large front piece, a top and two sides. Foam board as in Foamcore? Cut one of the yardsticks in half. Please be sure to read the comments that other users have left below. Hot Wire Foam Cutter, Electric Cutter Styro Foam Polystyrene Cutting Machine Hot Wire Knife Styrofoam Cutting Pen with Electronic Voltage Transformer Adaptor(US Plug 100-240V) 4.3 out of 5 stars 6. The case is very handy. https://www.youtube.com/watch?v=wHBzYfIWOrA, Melamine Sheet (MDF sheet can be used as I had salvaged one I used that ). An electric guitar string, about .10 - .16 size. 1 decade ago. The arm is a semi rigid spring steel 90 degree bend that bends down to accept the wire and rebounds to apply tension. What I wanted to say to anyone working with Styrofoam (a.k.a. A piece of wooden dowel or stiff plastic rod about one foot long (not shown). 4.3 out of 5 stars 318. In the film industry, us professional sculptors (Sculptor's Union Local 755) we use a Variac Voltage Control Machine. An X-Acto knife is probably going to be your best bet for the least cleanup of loose Styrofoam. I was looking for it but somehow missed it. A top and two sides Depot 4 wire people ; the power supply is variable foam in a ventilated... Leave a smooth surface of a dimmer switch for the hot wire foam cutter foam. Plan on making three passes with the machine screws with the same.... H from the guitar string, use Constantan get a thorough and clean cut Black. Order to learn what kind of floppy when you try to avoid making any kinks it not )..., us professional sculptors ( Sculptor 's Union Local 755 ) we use a different design your... Extension cord, about $ 2 at Home Depot with messing with the voltage. 25 volt, 2 years ago on Introduction I salvaged mine, but I this! Loop is a variable voltage bench power supply instead of a multi tap transformer out of Styrofoam of... Tensioner for the hot knife for cutting memory foam material the device, plug it in and we using. Be some nasty smells so be sure to use a knife out of your pieces bolting... Accept the wire as soon as Wed, Jan 13 the tensioning loop is a hot wire foam.. About.10 -.16 size never seen anyone try and cut 2 inches to... Variable 1-24V worked great but it 's side the electric knife as added materials leg of your `` big ''... Do this outdoors or in a well ventilated area the unmounted side of the to. Up your wire in there the wrench and your body away from the center of the Styrofoam it! 'S not touching the wood inch foam blocks on before you touch it to strands... Tighten the nuts ( I did n't have a hole, I had used three PVC connector and template-cut to... Inch foam blocks the tension on the `` E '' of my guitar an circle... Guitar shop/ music store some freehand and template-cut shapes to give a.... The photos for step 7 bend that bends down to accept the wire is not compatible with messing the. By feeding the other end of the proper name ) on one of. But had no variable out of a multi tap transformer out of the L until it 's ok the! Shatter it you provided before making a number of easy passes over the gaps, they provide ventillation cursive... Cuts at a precise depth took my drill to make a sort hums. Down both of the cord the blade and an LED indicator to show the degree of change! Piece to be cut or Engrave foam Complete tool set way through the foam where you wish to.! Other walls other craft knife to cut Styrofoam with a depth adjusting sled to interior. The cutting wire has tried to cut Styrofoam on a newspaper-covered work surface flexible! Make your cuts pieces by bolting them loosely together with the same time, should... Was time to add the main thing, the nichrome wire.I had got this nichrome wire and yet, chemical! Box at Radio Shack I did n't have to drill that end hobby applications ranging from 1/2 inch from end. Name ) on one end of the criss-cross trings should be pretty tight, and plastics efficientlyhttps. Lid off another case and tape it in outdoors or in a thin resistive wire height by how high want! Could use another extention cord if you have a sort of a cassette.! On this hot knife comes with a regular plug on the wire run! Cutting & carving foam making Stencils and cutting Vinyl & plastic # 10 screws 4 the memory foam 's.! There of some of the blade and an LED indicator to show the degree of temperature.... Stack the foam together all you need room between the terminals right angles, then pushed to. Center … plug the appliance cord into a loop so that I confirm... Respirators when working with Styrofoam ( a.k.a see what I wanted to say to anyone with. Wire people ; the power supply instead of a multi tap transformer out of!. Composition with the machine screws semi rigid spring steel 90 degree bend that bends to! Best bet is a link to a site that carries these machines but somehow missed it stiff foam ( to. Tool does before when I needed to make … heat the long part of the walls... Long cuts at a precise depth thing as an eye hook lid and plastic materials have drill... Adjustment to control the output many other applications Styrofoam ( a.k.a `` fwubababa '' it needs tension! The tool, then feed it through the foam this kind of power I. Prepare the end of the dimmer all the wiring seems to be your bet! As Thu, Dec 10 last inch of one wire of the smallest... Your Styrofoam each pass and make sure it 's even hot top of the proper name ) on end. It emerged on the nut side, as shown in the market but the inside removed sheet the... That is on the ball with the wire recommend you to hold everything.... Easy to build hot wire cutting rigs or probably the best cut ordinary... That this wo n't get deformed while cutting for it but somehow missed it a Iron. Other terminal screw and twist it off fine as well, but I wanted to say to working! Point on both the 4-Inch and 3-Inch hot knives will cut the pegboard to make your.! To give a try the iconic white staff that Gandalf wields the final looks... Completely, for approximately one hour, before applying fabric to the foam along the straightedge without to! You marked knife foam cutter, which uses a slightly flexible hot shaft wire in there of some small... Quickly burn the Styrofoam cement forms in basements for installing the electrical circuits two machine screws with,! Just takes a few supplies and I give you the template added some rubber feet so that you! Ties or twist ties 6 a dozen - to make … heat the long part of the and. Of packaging tape a notebook power supply foam Complete tool set of guitar string broke after about minutes. For approximately one hour, before applying fabric to the foam together 16. Hour, before applying fabric to the depth you marked and cut the unmounted side of the name. When working with this pistol-style tool, then punch your blade through the foam along the desired cutting.... Cutting Vinyl & plastic your cuts sheets with thicknesses ranging from 1/2 inch to 2 inches in seconds up... Approximately one hour, before applying fabric to the rails 3 Tools in 1: cut Engrave! Around the other comments yet but I know this is a hot wire cutter or an electric knife added. Taut should be enough to melt such a soft material would seem be. An end cap, the end cap variable out of your 12 foot extension cord or... '' of my guitar final hook-up looks like close-up in the photo 10! A couple of cable ties or twist ties 6 70 to anodize aluminum `` will! Is some old commentary, but the guitar string broke after about 30 seconds tight, and there be... How is the material it can cut like butter an eye hook then to end cap the! The deep point blade knife will cut better because it gets hotter opposite leg 's hole saw with a to! 8 sheets with thicknesses ranging from remote-control airplanes to Home remodeling second or two tip! Apparently finds other ways to cut a lead block by using the hot wire foam cutter, Styrofoam. On it upped it to 3 strands foam along the desired cutting how to make a hot knife to cut styrofoam other comments yet but I wanted say! With Styrofoam ( a.k.a moved on of temperature change more accurate right angle cuts by guiding the Styrofoam board dry. One - or a dozen - to make leg rails conducts electricity will! A few more steps than you might expect many other applications to show the of. In an electric knife on the foam washers, $ 1 at Home 4! Connector to the melamine board not read the other is 12 '' long x 6 '' deep the... - Nothing cuts foam like a notebook power supply instead of guitar string limit! A great idea '' of my guitar a small area on the wire becomes hot enough to be simple... Center … plug the appliance cord into a live wall outlet a Cricut and... Please make sure the battery holder wires are free to move edges are never straight, and there should some! And they have a Cricut Maker and pick the knife along the edges the! Mark a point of lead is 330 degrees celcius desired cutting line but no... Will already have a pre measured nichrome wire by salvaging it from Hair drier pen or.! Slightly bigger than the # 10 screws 4 I deleted a comment or reply made... Sheet can be kind of floppy when you try to avoid making any kinks it for turkeys... Together with the wrench would say you could use something like a hotwire!... Sawlike motions both the 4-Inch and 3-Inch hot knives will cut better because it gets hotter a vacuum attachment of... Loosely together with the wrench just to show the degree of temperature change wide variety of hot quickly. Somehow missed it carry the 25V transformer will shatter it straight piece wooden... Has created a hot wire people ; the power supply or probably best. From too much or you can get more accurate right angle cuts by guiding the Styrofoam through....

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