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.
Various materials can be used to make the wire although it is made from nichrome or stainless steel in most cases. This wire can be pre-formed to any shape a person wishes to produce. The wire is normally very hot that there is no need to touch the material for it to be cut. The material gets vaporized before it is even touched by the wire.
By use of a frame with springs or a bow, the wire is tensioned. If the diameters range between 0.008 to 0.020 inches, most people seem to like single strands of stainless steel wires. For frame-tensioned cutters, this diameter is suitable. For commercial applications, nickel-based alloy wire Rene 41 is mostly preferred. The alloy is preferred in commercial applications since it maintains tensile strength after reaching cutting temperatures.
This machine is appropriate for cutting several different materials. It is specifically appropriate for cutting through any thermofusible expanded foam. These refer to materials that normally melt at moderately low temperatures. Custom materials, flexible expanded polypropylene foams, polymathacrylimide, extruded polystyrene, and expanded polystyrene blocks are some of the materials that this machine can cut.
There exist various models of these cutters used today. They include, simple manual cutting tables, performed wires, template-guided manual tables, computer numerically controlled cutters, and push through slicers among others. Pre-formed wires are used by attaching them to handles. When in use, the operator needs to guide the wire manually to produced desired shapes. Handheld cutters operate similarly where they are guided by the operator manually so that it cuts freehand shapes.
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 are used mostly in packaging and construction industries. The table has tracks on each side for holding the wire. The tracks allow the movement of the wire to happen with a lot of precision. The tracks enable downward and upward motion. Horizontal tables can also produce angular cuts.
CNC capabilities have also been incorporated into foam cutting these days. This allows for even more accuracy and ability to cut extremely intricate shapes. However, accuracy of CNC machines can be affected by factors such as backlash of drive systems, stepper motors, and stiffness of races used to support end effectors. Tensioned wires are usually held by end effectors
Various materials can be used to make the wire although it is made from nichrome or stainless steel in most cases. This wire can be pre-formed to any shape a person wishes to produce. The wire is normally very hot that there is no need to touch the material for it to be cut. The material gets vaporized before it is even touched by the wire.
By use of a frame with springs or a bow, the wire is tensioned. If the diameters range between 0.008 to 0.020 inches, most people seem to like single strands of stainless steel wires. For frame-tensioned cutters, this diameter is suitable. For commercial applications, nickel-based alloy wire Rene 41 is mostly preferred. The alloy is preferred in commercial applications since it maintains tensile strength after reaching cutting temperatures.
This machine is appropriate for cutting several different materials. It is specifically appropriate for cutting through any thermofusible expanded foam. These refer to materials that normally melt at moderately low temperatures. Custom materials, flexible expanded polypropylene foams, polymathacrylimide, extruded polystyrene, and expanded polystyrene blocks are some of the materials that this machine can cut.
There exist various models of these cutters used today. They include, simple manual cutting tables, performed wires, template-guided manual tables, computer numerically controlled cutters, and push through slicers among others. Pre-formed wires are used by attaching them to handles. When in use, the operator needs to guide the wire manually to produced desired shapes. Handheld cutters operate similarly where they are guided by the operator manually so that it cuts freehand shapes.
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 are used mostly in packaging and construction industries. The table has tracks on each side for holding the wire. The tracks allow the movement of the wire to happen with a lot of precision. The tracks enable downward and upward motion. Horizontal tables can also produce angular cuts.
CNC capabilities have also been incorporated into foam cutting these days. This allows for even more accuracy and ability to cut extremely intricate shapes. However, accuracy of CNC machines can be affected by factors such as backlash of drive systems, stepper motors, and stiffness of races used to support end effectors. Tensioned wires are usually held by end effectors
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