Build Your Own Hot Wire Foam Cutter - Professional Tools for Modelers
ฝัง
- เผยแพร่เมื่อ 19 ก.พ. 2017
- A hot wire foam cutter is a must for anyone who is serious about modeling with foam. Foam is an extremely useful and versatile material when it comes to model making but to truly get the most out of it you need the right tools.
Building your own hot wire foam cutter is very easy and once you know how they work you can build all types of different foam cutters for an infinite range of jobs.
The foam cutter I’m making today is a tabletop precision foam cutter used for making very precise straight cuts.
Additionally by incorporating the temperature controller into the wiring I now have complete control over how hot the wire is. Controlling the wire temperature is vital for getting the perfect cut, too hot and the foam will melt before it even touches the wire… too cold and the wire will start to flex giving imprecise angles!
Materials
WOOD:
12mm MDF - Main cutting surface 30cm Wide 60cm Long
3mm MDF - Fascia 62cm Tall 30cm wide
30mm by 42mm Pine - Side support 2 strips 60cm long
30mm by 6mm Pine - Additional strip on side support 2 strips 60cm long and Controller block support
19mm by 42mm Pine - Cross section support 24cm long
MAIN ARM AND BASE
19mm Washer - Protects cutting surface from the hot wire
6mm Steel Rod - Main supporting arm at least 75cm long
6mm Saddle Clips - 6 in total
18 Gauge Galvanized Steel Wire - Hook in the top of the supporting arm
ELECTRONIS AND WIRES
12v DPDT Push On/Push Off Switch with inbuilt LED
2.1mm Bulkhead DC Power Connector
12v 8amp PWM Controller
10amp Screw Terminal Strip
Various Heat Shrink Tubes
Lead Solder
10amp 3mm Electrical Cable Red & Black
3mm Washer - times 2, Soldered to the ends of the output wires from the temperature controller
NICHROME WIRE
28 Gauge Nichrome Wire
3mm Washer - Attached to nichrome wire
5mm Diameter Spring, 1cm Long - Optional to absorb excess slack as nichrome wire heats up
CLAMP
3mm Diameter, 35mm Long Round Head Bolt
3mm Nut - times 2
3mm Washer - times 2
3mm Wing Nut
Tips for using the Hot Wire Foam Cutter:
A good starting temperature to aim for when cutting foam is 600°F, that temperature will vary depending on the density of the foam of course.
Try to use a lower temperature rather than a high temperature, the foam is more forgiving when cutting at lower temperatures and you’ll generally end up with a nicer finish.
Don’t forget as you can see in the video, you can make templates using regular printer paper and use that as a stencil for making cuts. This is where you need to ensure the wire temperature is not too high otherwise the wire will cut straight through the paper as well.
Avoid stopping during a cut, if you stop and start whilst cutting you may end up with fault lines where you stopped. Again a lower temperature will help minimize lines due to stopping and starting but for best result try to complete the cut in one smooth motion.
You can clamp sections of wood to your cutting surface to use as a guide for getting perfectly straight cuts, you can also temporarily glue thin strips of wood to the surface of the foam to get the same effect, essentially you’ll use the strips of wood that are glued directly to the foam as a guide allowing you to achieve all sorts of complex cuts.
MUSIC
Intro Music
Premium Beat - Green Screen
Background Music
Rhodesia by Twin Musicom is licensed under a Creative Commons Attribution license (creativecommons.org/licenses/...)
Artist: www.twinmusicom.org/
![[FULL EP.12] "นีโน่ - สเตฟาน" 2 หรั่ง แหย่รังมดแดง | เฮ็ดอย่างเซียนหรั่ง | One Playground](http://i.ytimg.com/vi/zLBmzfrx0u4/mqdefault.jpg)
I can't understand how you can have dislike on this video. This is exactly how a diy video should look. Keep up the awesome work luke!
lol, thanks mate 😀
Probably employees of a company who sell this equipment at a greatly inflated price.
@@petermilne2470 just saved me $200 CAD so i don't doubt it!
I can't understand dislike in every of his video !!!
lol, great comment, both funny and prob accurate.
Thanks for posting this ... I just cut my first foam 10 minutes ago and it works like a charm. My end use will be roughing in the scenic sections on my model railway. I can see getting some good use out of this tool over the coming months. Great stuff!
I don't know if I'll have the patience and dedication to make one as nice as one you made here, but you provided all the right information I needed to rig up something quick and dirty with what I had around my garage and get the job done. You're a talented craftsman.
Have said it before but will say it again, you don't post video's that often Luke but by God when you do they really are worth watching.
Great tips bud will most definitely be making one of these.
cool 😊 they are very easy to make, I put a lot of effort in the presentation of the foam cutter but in all honesty you can build it with bare minimum materials and it will still work great 😊 Thanks for the amazing compliment
Hi buddy, can you support my channel?
I've just made mine, thanks for this tutorial - it gave me the confidence to try rather than keep struggling away with a knife!
I only need a handheld foam cutter for more freeform work, but this was a great little build:)
Also the nichrome calculator is a great tool - takes the guesswork out!
Only man alive who could make a video about building a foam cutter interesting
Thanks again, my man
ha ha ha 😊 so glad you enjoyed it Rob, thank you 😊
Rob The Dog the king of random made this first
Crêpe this one has a cleaner look, but grant's is better, it has a variety of features that make it more usable from being able to separate and be used handheld, or cutting at different precise angles depending on the need.
Rob The Dog ggh
This one can have the wire removed and inserted for inside and intricate work. This one is better than Grant's and a whole lot simpler as well
It’s really refreshing to see a video tutorial that you can get an amazing results and you’re not using items lots of us haven’t got! Subscribed and I’ll definitely be giving this one a try
I love how you’re Australian, because it fills me with more confidence that whatever you’re using can be found at my local Bunnings.
One of the best DIY videos here on TH-cam EVER!
Thank you and greetings from Portugal.
Thank you for this professionally presented video. The project is exactly what I've been looking
for..
The spring is a necessary part and something most diy'rs omit from the build. The foam cutting unit looks really professional to me and I would be proud to have it sitting on my bench as a leading workhorse of a tool. Thanks very much for sharing and saving us money. Happy holidays! :-)
I built a very large one in the past, the cuts had to be about 40 inches long. Now here I am doing research and preparing to build a smaller unit.
You want higher, consistent tension for straighter cuts, when the wire is up to temperature. I instead used a turnbuckle instead of a spring to tension the wire once it was hot.
Wanted to say thanks for this video. This is definitely the cleanest looking table I have seen on youtube. I just need to gather the hardware for this and will be ready to get going on the build. I will have to modify this a bit to fit my needs, but this video has been invaluable for me. Thanks!
I don't really need foam cutter...but I genuinely enjoyed this video. Thanks for your projects, they are marvellous!
Thanks mate 😀
Thank you, this is the most informative video I've seen. The main thing for me is finding the power range requirements.
Very professional looking, it's very impressive!!!
Beautiful, clean workmanship!!!
Thank you for sharing.
Hi Luke,
Another great tutorial, how to build a useful device with ease and grace. You're not only a very good modelist, but a talented educator!
Sincerely,
Alexander
Wow 🙂I really appreciate your kind words, thank you 🙂
agree 100%
This is a perfect tutorial video. Amazing work. It is exactly what I needed to see. This will be perfect for cutting out foam that will be used for a mobile tool chest. I like the idea that every tool will have its place. The chests silence will be pleasing as well. Cheers to a TH-cam video done right.
Thank you for this, just ordered everything to do it!
3:35 Right side of screen, hello Mr.Spider!
Well, he is from Australia
yeah, as long as they don't run up your arm 😊
I also seen it lol
disable HD view if you don't like spiders :D
I think the spider wanted to have a closer look at what I was doing... or perhaps looking for real estate and realised everything was fake(ish). So he ran away disappointed. 😀 LOL
Great work! As a tip from a Electrical Engineer and DIY-er i recommend getting a cheap wire-crimper and some circular terminal instead of the soldered washers. They're cheap and gives a good solid mechanical and electrical connection.
I didn't even think about that! That is a great idea 😊 Thanks for your advice.... Greatly appreciated 😊
Now, this is a good example of a "Professional"! This is the slickest most professional instructional video with respect to content, and presentation I've seen so far! Very impressed!
It's a just a complete pleasure to watch someone take this much care and pleasure in their hobby as much as you do Luke. Thanks for the excellent content as always :D
thanks Snuggles 😊 I spend quite a while putting them together so it's great to see how much you appreciate them 😊
Nothing more relaxing than listening to an aussie explain DIY haha! Cheers pal I'm gonna give this a go
I have been wanting to make one of these for a while now. Your video is the best one that I have seen to simply explain as well as make it seem simple enough to make on my own. Thanks for the inspiration.
You are most welcome 😀 Glad you enjoy them. 😀
I just started prop designing. Thank you for this...
Fantastic build, thanks for sharing. Just might have to build one of these.
Thanks for sharing this how to along with the wiring diagram & website for calculations. Very nicely done wire foam cutter, & the finish adds a professional look to it too!
hell yeah! thanks for your guide. Now I can build my own railroad model
Love it thanks for watching... also i would like to see how you made the little Razor blade chopper like watch video's
You make it look so easy. Clear and concise instructions and tips and a really professional looking end product, cheers mate.
probably the clearest tutorial I have seen on the subject.
10/10 - Hot Wire Foam Cutter reviewer
thanks Dewitt 😊
superb and a professional step by step explanation. i have been seeing other foam cutter videos for sometime and none of them even come close to what u have here. am thoroughly impressed Luke.
Thumbs up for you, my good man! Very professional tutorial, greatly appreciated.
Great job with this, Luke! I am researching for making a nichrome wire heated acrylic bender, with a similar electrical design. You've done a great job with that.
You can use the heating element of an old clothes dryer.
Have been a fan of yours for quite some time, thank you for your DIY videos. Saw this years ago and now need one!!
I've built several foam cutters of various designs over the years, but this is one of the most professional looking I've seen. Excellent work!
wow thanks mate for the amazing compliment 😁 Glad you liked it
Absolutamente incrível!! 😃 parece mesmo um equipamento profissional!! 😉 continua a postar vídeos de ferramentas e equipamentos, são bastante úteis.... continua o fantástico que tens feito... Cumprimentos
Lord Luke towan, you keep every promise you make. We are already delighting with a new production of yours. It is a pleasure to be your follower. I hope it will result in seeing so many beautiful things and that I will be able to develop as much skill as you. Thank you very much.
LOL! 😁 Thanks mate, glad you enjoy my productions. Will do my best to keep my followers happy. 😁
Gracias a usted. Y disculpe por escribir por momentos en Español que es mi lengua nativa.
Luke Towan awesome tutorial, im so glad , you are the " Maestro Rochi" (Dragón Ball Z, LOL) , una herramienta muy útil, un vídeo profesional y explicado paso a paso, ( necesitas alguien que traduzca tus vídeos al español, son de gran ayuda ) :D
That soldering wire to a washer trick is awesome!
Definitely gonna build one of these over buying a 120 dollar table top foam cutter! I'm just getting into building foam terrain for DND stuff. Thanks for the video!! I'll definitely use it as a guide!
For any model building this is an amazing video. So well shot and edited, full list of materials, and straight to the point. Bravo
Thank you 😀 It's good to see you know how much hard work gets put into my tutorials. Your words are encouraging and motavting.
How all instructional videos should be produced...excellent work!
I've never seen a wing nut spin so smoothly as yours does. ;) Great video - thanks for making it!
You're smart as a Bond villain. Thank God you use your genius for good!
Thank you Rasdock for your positive comment. Without my wife's support, keenness and understanding, I wouldn't be able to enjoy my hobby as much as I do now. She's so encouraging and gives some pretty good ideas. 😁
Another fine project! Loved it 👍🏼
Thanks Sinlo 😊 Glad you've been enjoying the videos 😊
For bending the steel rod use two closed end box wrenches and slip them over the rod. They can then be used almost like a tubing bender to shape the rod. Works for most bends up to 90 degrees. A little heat from a heat gun (the type used to strip paint) will relax the steel a little bit without having to use a torch. It won't get near as hot but it will be enough to help make smooth bends that will look much better than cold bent steel. Only heat the area where you will make the bend.
It's great to see that quality circular saws made in Germany are available and being used in Australia :-)
Best how to I have seen. The detail of the power required and how to calculate title was very helpful. We’ll done
Thanks for posting! I just finished my build based off this design, including making the sides too short and having to extend them a little. To all the people wondering if you get shocked touching the rod... you do not. Not even a little. It is the same as touching one end of a dry cell battery.
Yeah, 12V will do nothing to you (I believe you don't need safety elements in a circuit up until 24V), which is why it's used in cars. But in this case it's even better, like touching the end of a battery that's at the same time connected to the ground, i.e. the current doesn't even want to flow through your body, it has a much better outlet.
Only if your ground cable accidentally comes off sometime down the road do you get the full 12V (or more like 5V depending on how the dimmer is set), and you'll probably notice quite quickly that something's wrong as your cutter doesn't work anymore ;)
So yeah, no need to worry, but it's never wrong to consider all risks. The temperature of the wire is probably more dangerous than the voltage on the rod, especially if you have pets or children in the house.
Kudos for following step by step, including the missteps XD
Thank you. Useful ok 👌 info
Hi buddy, can you support my channel?
Can't believe you got any dislikes on this video. Excellent, to the point, great craftsman and design, can't wait to make it.
I was about ready to buy one but your design is far superior to anything I have seen on the market, Thanks so much for making the video.
Always a pleasure and great inspiration to watch your awesome and high precision work. You are the real "Cool hand Luke"!
👍Wow, thank you for your positive feedback 😀
Very well done. THANK YOU!
The video is beautiful. Health in your hand. It's very informative. It's the best work I've seen lately.
A super helpful and informative video, Luke. Thanks for taking the time!
Great work.. must say you bring shame to other carpenters when I saw your neat work. KUDOS 👍
Looking great! When I build mine im following this video. Great work!! :-D
That looks like it was shop bought. Excellent build !!!!!
GREAT DIY VIDEO! excellent camerawork, clear audio with nice background music, brief and precise information...nice and clean work too. I'm already a fan, thanks for sharing.
your projects are always worth to watch, waiting for the next one now.
Thanks mate. 😃 Am in the process of making the next video. 😃
Awesome video, thank you very much. I will barely give a recommendation for whoever uses it and that is to be careful with your fingers when working because they are very close to the wire and in any movement error it can burn or cause an injury. I recommend using resistant and thin gloves to be able to maneuver the pieces.
Luke always amazes, he makes the most intriguing things that made me subscribe!
wow, thank you 😊 Glad you are still enjoying the videos 😊
Luke Towan Absolutely!
Totally need to get myself one of these
Not many people list the wire gauge .. you do. Perfect :)
I dont make things like Luke and so many others like him.....but I love watching things being made. I cant put my finger on it. But I have honestly viewed Luke's videos the moment posted. Cuz I've subscribed. And then repeatedly for the simple viewing pleasure of Luke and his simple execution of the project, dyi low dollar solutions. Rhe lightning is great, area clean and all things ready and organized. I dont watch let alone rewatch modelers LITERALLY in their basements with crap everywhere you could hardly make sense of what ur seeing. Yea long comment. But it's all true. I love being subscribed to Luke!!!!!!!!!
The best of the best Hot wire foam cutter home made like a pro just great love to make one for my self thanks you my friend for this great video .
It take two minutes to dislike but just imagine how much efforts it takes to prepare this video's to us....Good Job 👍
Nice build Luke! Your videos are the most relaxing ever. It's wonderful watching you build things. Thanks. Cheers, Dan
thanks Danny 🙂 glad you enjoyed watching
Thanks, you are really great. Congratulations from Ecuador.
Very cool, especially that it's scaleable. Thanks.
This video is very helpful because I did not know how to make a foam cutter but now I do.
Great stuff!!! Thanks mate. I'll be building one of these in the near future. Awesome...
Just watched this. Well presented, clear and straight forward video. Thank you.
Awesome! Thank you so much for creating this video. You're videos are very inspiring! I'm hoping my sons will watch this and get inspired enough to want to try some of your projects. My eldeset is going into joinery and middle son has a interest in electronics so would make the perfect collaborative project, fingers crossed :-D
Great video Luke, looking forward to making one of these too. Well done my friend!
No worries mate 😮
Ahhh I love your tutorials so much :) Calm, neatly executed and really easy to follow
Thanks mate 😊
Great build guide!
thank you 😊
great project, thanks for sharing!
Love it very neat job! Good to see some Bunnings tools come out 😏 the ozito saw and ryobi circular saw, black and decker drill. Nara wire and the little power pack adjuster love it! Definitely subscribing
ha ha 😀 Yeah I spend way too much time wandering around Bunnings!
Finished product looks very professional. Great job!
CONGRATS...SPECTACULAR!!!! SUPER VERY HELPFUL!!!!!
cool! looks much better than mine. Subscribed!
Thanks mate 😃
Hi, this video is incredibly clear, you did a really good job!
Does it work aswell with other types of materials like polyethylene foam?
Great video and great cutter! Best video on these I've seen so far. Thanks :)
Thank you my friend, I am glad to hear that you have answered me. Today I see your answers and thank God today I found what you indicated. It is excellent, well I am in the learning stage, I do not design almost anything. First of all I'm seeing that I buy, I would be glad to give me some suggestions on where to start in the ferromodelismo, copy all his tutorial videos and see them again and again before spoiling expensive and inaccessible stuff where I live. Please give me some idea to start my model in relation to material rodande, always thinking of a simple economy because I am of limited resources. Well I say goodbye, thank you for your attention and I hope I do not overwhelm you with my requests. Sincerely.
good choice! the pencil~
I roughly followed your design, but instead of having the metal bar I used 2 pieces of wood to make an inverted "L". I also used a guitar machine head for tensioning the nichrome wire (you can tension the wire as it heats up). I also wired in a cigarette lighter socket and I can now plug in a hand-held cutter.
Wow! One of the best DIY hot wires out there. Very well thought out and explained. Excellent work.
SPIDER! 3:34!
Thanks mate 😀
Thank you so much for posting this. Now there is another way for me to make 3D designs with my own hand-lettering.
May Allah reward you for generously sharing your knowledge.
Great Vid. I based my own build on yours
I bought the same pwm controller as you but instead of creating a higher base, I just unscrewed the box and removed the potentiometer to mount on the side.
I mentioned you to Adelaide moulding supply and they watched some of your videos after I said you recommended them in one of your videos, so lucky youre a local ! Makes my shopping easier.
ha ha cool 😊 thanks
Excellent video. Well done and well explained. I may consider building one with a fence as to slide the foam in a straight line for straight cuts. Any suggestions how to add an adjustable fence. Thanks...
Philip
Sweet video as always. Yet another gadget-tool that's homemade and better than the shop ones. Any issues you can get spares lol. On my list for making once the new roof is on our workshop and it doesn't leak.
Man... Amazingly well done. I've never saw someone be so careful about the overall look of what they're doing... Beside you and myself. Congratulations to the great job! And be sure I'm going to make my own version of it. :)
ha ha ha 😀 thanks mate... I can often spend way too much time making things look good when they don't really need to 😀 Have fun making your own version
Luke Towan I know what you mean, bro. I have the same problem. LOL You should see my two (small, to use by hand) hot wire cutters... Both made of layers of cardboard and the outside I made one with black EVA and the other with a hard and strong kind of paper. LOL But I didn't make videos at the time. (Now I make, but in Portuguese - I'm from Brazil.) Almost every time I paint and so on... :)
Hi, there. Great video. One question. I have kanthal 0.2 mm wire. Can I use it and if so, how to calculate needed power? Thanks.
Very nicely done. I enjoyed watching and learned. Thanks.
3:35 SPIDER! Anyway, great vid, and thank You for materials list :-)
I actually thought it was a bought unit until I started watching the construction, excellent work and video
This is much cheaper than buying a wire cutter! I'm stoked to build this.