Overview of CNC Foam Cutting

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A CNC Foam cutter is a machine that cuts blocks of foam into a variety of different shapes and sizes through the use of a computer that fully automates the process. As you can imagine, the name of this process makes a lot of sense because its called hot wire foam cutter, and its the hot wire cutter that is used to make a cut in the foam.

Usually the wire is made from stainless steel, nichrome and the wire can be very thick. The wire is heated using a process called electrical resistance which means it gets hot enough (around 200 degrees centigrade) to vaporize the foam before the wire makes contact with it. What happens because of this process is a smoother cut and you can product a variety of shapes and sizes.

Depending on the length of the wire, the process will cut a shallow or deep cut. As you can imagine it is not good when the wire sags so there are machines that are keeping this wire very tight when it makes the cuts. On many CNC Foam machines this wire is held vertically so that it doesn’t create the problem with sagging.

These shapes are cut by the cutting wire that is attached to the machine. They will cut either polystyrene or polyurethane blocks. The types of foam that a CNC foam cutter can cut include anything that is thermofusible and expanded. What this basically means is that the foam has to be able to melt at one of the lower temperatures. Some of them include:

§ Polystyrene -- these are blocks of balls that are expanded.
§ Polystyrene -- this is extruded foam and comes in a variety of colors that include green, pink, purple or gray and these are usually plates that are smooth.
§ Polymethacrylimide -- a very expensive material and it is rigid foam with a low density.
§ Polypropylene -- which is flexible and expanded and can be a solution to protection from shock.
§ Polyethylene -- these are foams that are tear resistant and flexible.

With the CNC Foam Cutter you can form a more prism like or tapered shape in the block of foam. A hot-wire that is under a high tension to cut the foam. There are two different types of components one is called a race that controls the tensin of the wire and the other are the stepper motors that work on precision and accuracy.

Some CNC foam cutters also offer different attachments like a lathe and this allows the machine to use either preformed or stretched wire. Also the machine is able to cut a variety of shapes including spirals or blocks of ornamental structure like balusters for stairways or planters.

There are a variety of uses for foam cutters that include making signage, model airplanes, protyping, lost foam cutting and more. The CNC Foam Cutter is a flexible machine and is only limited by the imagination.
Although many people prefer to purchase a CNC foam cutter there are also plans on the Internet that show how to make them inexpensively for hobbyists and others who are interested in working with foam.

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