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.
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 suitable for cutting a wide range of materials. It is particularly suitable for cutting through all thermofusible expanded foams. These are materials that usually melt at relatively low temperatures. Some of the materials the machine can cut include expanded polystyrene blocks, extruded polystyrene, polymethacrylimide, flexible expanded polypropylene foams, and custom materials.
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.
A horizontal table is used in securing foam work pieces in place when using hot wire foam cutting tables. The wire, either vertical or horizontal then cuts through work pieces placed on the table. These vertical wires are used by hobbyists for cutting small but sophisticate shapes such as letters. Only prismatic members can be cut using vertical tables.
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.
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 suitable for cutting a wide range of materials. It is particularly suitable for cutting through all thermofusible expanded foams. These are materials that usually melt at relatively low temperatures. Some of the materials the machine can cut include expanded polystyrene blocks, extruded polystyrene, polymethacrylimide, flexible expanded polypropylene foams, and custom materials.
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.
A horizontal table is used in securing foam work pieces in place when using hot wire foam cutting tables. The wire, either vertical or horizontal then cuts through work pieces placed on the table. These vertical wires are used by hobbyists for cutting small but sophisticate shapes such as letters. Only prismatic members can be cut using vertical tables.
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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