Machines for cutting foam: the principle of operation, types, prices. Homemade foam cutter - buy or do it yourself? Homemade foam cutting machine

01.06.2020

In today's market building materials products made of polystyrene foam, expanded polystyrene and other polymeric substances have gained wide popularity. Possessing excellent thermal insulation and decorative qualities, such materials have characteristics manufacturing and processing.

Features of processing polymeric materials

Cutting polymeric materials has the following features:

polymeric substances have high elastic properties;
polymeric substances have a low coefficient of plasticity;
the process of mechanical destruction occurs without plastic flow and is lumpy in nature;
the process of processing polymeric material requires the impact of a small cutting force.

The high elastic characteristics of such substances cause reversible deformation of the layer lying within the cutting surface. This leads to mutual contact of the cutting tool with the material and, as a result, an increase in the friction forces between them. For this reason, it is recommended that foam plastic be processed only with a sharpened and lubricated tool.

The amount of force applied affects the accuracy and quality of processing. The correct calculation of this effort allows you to assign the optimal parameters of the equipment and evaluate the magnitude of the processing error.

Types of CNC machines for cutting foam

CNC machines used for processing polymer products are classified according to several criteria.

Depending on the design, CNC equipment can be:

portable;
stationary.

Portable. These models are characterized by simplicity of design and the possibility of their unhindered movement. In addition, they can be assembled by hand. These units are used for a small amount tasks and the release of small batches of goods.

Stationary. They are installed for a long time and are characterized by high weight, dimensions, complexity of the device and versatility. Often such machines are equipped with numerical control (CNC) used to automate the process of cutting large volumes of products.

According to the processing method, CNC machines are:

With longitudinal and/or transverse 2D cutting. In machines of this type, the movement of the cutting mechanism is carried out in one of the spatial axes.
To obtain complex volumetric figured products (3D cutting).

In machines of this type, the cutting mechanism moves along the X and Y axes of the spatial coordinate system using mechanisms controlled by computer program control.

Classification by cutting tool

Depending on the type of cutting tool, CNC machines can be:

hacksaws (a sharpened hacksaw blade is used as a cutting element);
milling machines (the main cutting body is carbide cutters);
disk (cutting is carried out by hard-alloy disks with teeth);
wire (string);
(material is cut using laser radiation).

Wire equipment with CNC foam cutter is the most widely used. As a cutting tool, thin nichrome threads are used, which have increased current conductivity and tensile strength.

For information. The manufacture of 3d products of a round shape can be included in the kit of each CNC equipment.

Overview of popular models

In modern conditions of industrial processing of polymeric materials, CNC machines of both domestic and foreign production are used. To the most popular domestic developments include CNC machines for cutting foam from Apparatus, SRP, Cyberstack, Antum.

Most popular models CNC foam cutting machines of domestic manufacturers are presented in the table.

Model name	Type of processed products	Working mode	Cutting tool	Workspace	Power consumption, W	Machine weight, kg	Cost, thousand rubles
Products from Apparatus
ARPU-3(4)D-60-60-60	styrofoam, expanded polystyrene, sheet plastic	2D, 3D		60x60x60	from 400 to 1300	70	65
ARP-4D-90-60		2D, 3D	Nichrome thread	90x60 with variable string length	no more than 350	45	85
Antum's products
FCM6060	Styrofoam, expanded polystyrene, extruded polystyrene	2D, 3D	Nichrome thread, milling machine	60x60x60	from 400 to 1300	65	85
A06-U	Styrofoam, expanded polystyrene, extruded polystyrene	2D, 3D	nichrome thread,	120x60 with variable string length	no more than 400	50	50
Cyberstack products
CNC Foam Cutter - 2017	Styrofoam, expanded polystyrene, extruded polystyrene	2D, 3D	Nichrome thread	100x135x250	no more than 2000	110	190-200
SRP products
SRP-3221 "MaxiUniversal"	Styrofoam, expanded polystyrene, extruded polystyrene	2D, 3D	Nichrome thread	150x125x220	no more than 1500	100	180-200

From foreign manufacturers of CNC machine tools, the products of firms have proven themselves well:

Proxxon (Germany);
FUBAG (Germany);
SPARKY (Bulgaria);
Megaplot (Poland).

Lately on Russian market there were samples of CNC machine tools made in China, for example, by Limac.

Making a machine at home

Due to the high cost of factory-made CNC machines, some craftsmen have come up with ways to make such equipment with their own hands.

Creating a machine for 2D foam cutting at home will require the use of the following materials:

workbench (work table);
step-down transformer 220/12V;
rheostat or LATR (adjustable laboratory autotransformer);
nichrome wire 0.5 m long;
metal springs.

Do-it-yourself foam cutting machine diagram

As a supporting structure for equipment, a sheet of plywood, fiberboard, chipboard, a textolite platform 10–20 mm thick and with dimensions corresponding to the dimensions of the planned product can be used.

A base sheet is laid in the center of the workbench, along the edges of which racks for the filament are installed. At the required height of one of the racks, a cutting wire is attached. The second end of the cutting wire with a spring connected to the counterweight is attached to the second post. The spring in this case is designed to tension the thread during its heating.

By connecting in series the ends of the primary winding of the transformer to the 220 V power supply network, and the output ends of the transformer through a rheostat (LATR) to the ends of the nichrome filament, it is heated. With the help of a rheostat (LATR), the heating temperature of the thread is adjusted and the optimal material feed rate is selected.

Designing a machine for 3D foam cutting with your own hands will require an increase in the number of nichrome threads with a corresponding complication of the electrical circuit.

Making a machine for processing polymeric materials with your own hands will help save a significant part of the funds that can be spent on the purchase of consumables.

Despite the huge amount of insulating materials (which, by the way, is constantly growing), as well as the increasing popularity of mineral wool, polystyrene still occupies a leading position and does not plan to give them up. If it is planned to insulate the floor in an apartment or basement, then cutting polystyrene foam is quite manageable with the help of improvised tools, but if we are talking about significant volumes or unusual tasks, then a special device is needed - a foam cutting machine.

Foam Cutting Machine

Machine classification

In today's market, such machines are presented in a fairly large variety. In this case, you can purchase a special laser cutting machine or, alternatively, try to make something similar with your own hands.

By the way, all machines are conditionally divided into the following categories:

portable units (vaguely resemble a knife);
CNC units;
for cutting across or horizontally.

Design features and principle of operation

Even despite the fact that machines exist in a variety of modifications, the principle of operation for all of them is in general terms the same. The edge heated to a high temperature passes through the foam layer in the desired direction, like a hot knife through butter. In most cases, a fishing line is used as such an edge. In the simplest models, there is only one such heating thread, while in more advanced devices there can be several at once (up to six strings).

Note! If cutting of molded elements is planned, then special attention should be paid to the length of products that can be processed.

As an example: the SRP machine, which is also used for cutting the described material, is equipped with strings over 2 meters long, and in one run it can cut about 12 linear meters. meters of material.

Specialized machines and their prices

Often, foam is used not for insulation or soundproofing structures, but for the manufacture of advertisements or in interior design. This is possible due to the use of special machines designed for curly cutting. Characteristically, with the help of such equipment it is possible to process the material simultaneously in 2 or even 3 projections. If desired, you can produce the most complex elements, such as gears, chess, miniature models of cars, various figures, any decorative ornaments.

Below are the most popular devices on the domestic market, as well as the average market price for them.

FRP-01

This unit owes its huge popularity to the simplicity of its design and versatility. It is possible to produce molded elements, figures and letters for signboards, insulation boards and so on. The control of the device operation is carried out by means of a computer program included in the kit.

The approximate cost of the unit is 110-115 thousand rubles.

Machine FRP-01 for cutting foam

SRP-K "Kontur"

Another great model that allows you to make various parts facade decoration and formwork for pouring solutions. In this case, the control is manual, but the power consumption is relatively low (about 150V), and it is very convenient to transport it.

The average market value is somewhere 42.5 thousand rubles.

Self-made cutting machine

There are a number of ways to build a foam cutting machine - from the simplest (hand tools) to the extremely complex in execution. Let's briefly consider each of them.

Method one. Manual cutting of styrofoam

The simplest and at the same time affordable method is cutting the material with a knife. It is important that the knife used for this has serrations and is lubricated with automotive oil before starting work (this will reduce noise and optimize the procedure itself). It is also worth noting that this is the slowest of the methods, so it is only advisable in the case of a small amount of material.
Styrofoam can also be cut with a hot string. To do this, hammer in a couple of nails, pull a nichrome wire between them and connect the power supply to it. The main advantage of this method is high speed (one meter is cut in 7-8 seconds) and a neat cut. But there is a significant disadvantage: such a procedure is harmful to human health.
The third method is known as "cold string" cutting. In this case, a steel string is used in the same way as a two-handed saw blade. This method is quite productive.
Similarly, you can cut the foam with a conventional hacksaw.
Finally, there is a professional hand tool, finished reminiscent of the hot string mentioned above, only more refined. With such a tool, the work is done efficiently and quickly, it is possible to use curly nozzles.

Video - Cutting polystyrene foam with nichrome

Method two. Homemade machine on the table

Be that as it may, cutting polystyrene foam manually, even with one of the above tools, is quite difficult. The material may burst or crumble, nothing can be done about it. The hot string partially solves the problem, but what if the amount of work is too large? There is a way out - you can build a stationary cutting machine at home.

First, everything you need is prepared. When creating such a device, you will need:

a large table (ideally, each side should be at least 2 meters);
a string with increased resistance (in the presence of an old electric heater, it can be removed from it);
iron springs, which are characterized by low electrical conductivity;
laboratory transformer (LATR), which turns a 220-volt current into a 24-volt one.

In addition, you will also need a string height controller. They can be, say, a pair of beams, and it is between them that the cutting string will move along with the holder.

Note! A transformer is not always required. This moment depends solely on what material is used in the manufacture of the thread. And if it is chrome-plated, then a current of 220 volts can also be used. Although we note that when working with such power, you must strictly adhere to safety regulations, otherwise the consequences can be the most dire.

If the foam cutting machine will operate from only 24 volts, then there can be no danger to the body. You simply will not feel such a current, and after an accidental lesion, you just need to rinse the affected skin area with water.

We also recall that if the foam is cut with hot metal, then toxic substances will inevitably be released. For this reason, work must be done exclusively in a special mask, and the room must be well ventilated; otherwise you can get poisoned. While cutting outdoors is preferable, this can only be done if you have your own yard.

To make it more convenient for you to assemble the structure from prepared parts, we have given below a detailed diagram of the future machine.

Equipment necessary for the production of foam Previously, we talked about the equipment that is necessary for the production of foam, in addition to this article, we advise you to familiarize yourself with this information.

Method three. Homemade machine (in the absence of a suitable table)

If you do not have a table of suitable dimensions, then you can make a base for the unit from plywood, a regular board or chipboard. The algorithm of actions in this case should be as follows.

Preparing everything you need

The principle of operation of the machine described above is also based on the use of hot metal. If you run a hot wire over the material, it will be easy to cut, and the cuts will be perfectly even. In the workflow, in this case, you will need:

The cutting element will be a nichrome spiral. As already noted, it can either be purchased or removed from the old heater. Tellingly, the thickness of this spiral can vary between 0.5-1 mm, although it would be better if it is 0.7 mm. As for the length, it depends on the dimensions of the material that will be cut.

Note! An important element is the laboratory transformer. If you don't have one, you can make something similar out of an old transformer and a car battery charger.

There is another option - you can take a power supply from a PC, where 12 volt wires (black and yellow) are connected to the spiral.

For a homemade machine, an output voltage of 7-12 volts is sufficient. Another important point: The thickness/length of the filament must be adjusted to match the voltage. If the heat is too strong, the thread may even burst. At the same time, if the warm-up is weak, the cutting procedure will noticeably slow down.

Finally, the battery itself from the car can serve as a power source. This is useful in cases where there is no electricity.

Assembly directly

Below is step-by-step instruction unit assembly.

Step one. We take a thread from nichrome and attach it to the springs. The springs themselves are put on the M-4 screws, and those, respectively, are screwed into the prepared racks.

step two. We pre-press the iron racks into a chipboard sheet, countertop, plywood (or another surface that will serve as the basis for a foam cutting machine). The thickness of the base, as well as the height of the posts, should be determined by what the needs of the user are. With a base thickness of 18 millimeters and a support height of 28 millimeters, the screw, being completely screwed in, will not be able to pass through the base; and vice versa, being completely unscrewed, it will be able to cut material with a thickness of 50 millimeters.

Note! If further cutting of thick sheets is required, we will remove the small screws and screw in longer ones instead.

Step Three. We make holes in the base for the purpose of pressing. It is important that the diameter of these holes is approximately 0.5 mm smaller than the diameter of the stand itself. Next, using a hammer, we drive the racks into the holes, but we pre-treat the sharp end edges with sandpaper (this will greatly simplify this procedure).

Step Four. Before screwing the screw into the rack, we take some suitable tool and cut a small groove under it (the screw) with a hat. To do this, we clamp one end with a screwdriver, put a file under the hat and initiate rotation. What is this groove for? First of all, in order to fix the wire motionless, otherwise it may move during the adjustment process.

Step Five. We fix the wire: first to the springs, and only then to the screws themselves. This is necessary so that it does not sag, heating up and, accordingly, lengthening somewhat.

Step Six. Having finished with all the fasteners, we take the nichrome wire and fix it. The fastening method that we use here is called “crimped twisting”: it allows you to create the most reliable contact between the cable that conducts current and the wire. It is also important that the cross section of the copper cable is at least 1.45 mm².

step seven. We clean the insulating layer from the ends of the cables by about 2 centimeters. We wind copper conductors onto the wire where it is already fixed on the springs. One of its ends, using pliers, firmly hold and wrap the conductor with it. Such a winding allows you to achieve the maximum area of \u200b\u200bcontact of the wire with the wire, and when the machine finally starts working, the connections will not overheat.

Step eight. Next, we make the withdrawal of conductors conducting electricity, in the form of a loop, so that in the future it will be possible to regulate the procedure for cutting the foam. In addition, we make holes in the base and pass wires through them so that they do not get confused during operation. After that, we fasten them on the other side using staples.

Note! Experts advise laying the cables together and twisting them, forming a bundle that is not too tight. In this case, they certainly will not get confused.

Step nine. We solder the terminals to the ends of the wires, which will be connected to the energy source used.

So, the foam cutting machine is almost ready. Note that the construction created according to the above scheme is quite enough for the conditions home use. Moreover, if desired, it can also be used as a device for curly cutting polystyrene foam.

Video - Creating a device for cutting polystyrene foam

During the cutting process, average speed foam movement. If it moves too fast, it will most likely crumble, and if it moves too slowly, the ends of the sheets will begin to melt.
If work is being done on a site without electricity, then you need to connect 3 9-volt crowns together and use them as an energy source. In this case, the machine will be able to work for about 35-40 minutes.
It is undesirable to use car batteries for this, since they, despite the insignificant voltage, are also distinguished by a large current that can damage the string. And it’s good if it simply bursts, because it can happen that it splashes with hot metal.
The foam that will be used to insulate the bath must be thick. Moreover, thick material is easier to produce (and it is not particularly popular), which means that it will cost less than thin material.

Heat and sound insulating building materials on the market are presented in a wide range, these are foamed polyethylene, mineral and basalt wool and many others. But the most common for insulation and soundproofing is extruded polystyrene foam and foam plastic, due to its high physical and chemical properties, ease of installation, low weight and low cost. Polyfoam has a low coefficient of thermal conductivity, a high coefficient of sound absorption, and is resistant to water, weak acids, and alkalis. Styrofoam resistant to temperature environment, from the lowest possible to 90˚С. Even after decades, the foam does not change its physical and chemical properties. The foam also has sufficient mechanical strength.

Styrofoam also has very important properties, these are fire resistance (when exposed to fire, the foam does not smolder like wood), environmental friendliness (since the foam is made of styrene, even food products can be stored in containers from it). Fungi and foci of bacteria do not appear on the foam. An almost ideal material for insulation and soundproofing in the construction and renovation of houses, apartments, garages, and even packaging for food storage.

Styrofoam is sold in building materials stores in the form of plates of different thicknesses and sizes. When repairing, foam sheets of different thicknesses are often needed. With an electric foam cutter, you can always cut sheets of the desired thickness from a thick plate. The machine also allows shaped foam packaging from household appliances turn into plates, as in the photo above, and successfully cut thick sheets of foam rubber for furniture repair.

How easily foam is cut on a homemade machine, the video clip clearly demonstrates.

If you want to make a cutter for foam plastic and foam rubber, many are stopped by the difficulty of organizing the supply of supply voltage to heat the nichrome string to the desired temperature. This obstacle can be overcome if you understand the physics of the issue.

Machine design

The basis of the device for cutting foam was a chipboard sheet ( chipboard). The size of the plate must be taken based on the width of the foam plates that are planned to be cut. I used a 40x60 cm furniture door. With this size of the base, it will be possible to cut foam plates up to 50 cm wide. The base can be made from a sheet of plywood, a wide board, and the cutting string can be fixed directly on the desktop or workbench.

Stretching a nichrome string between two nails is the limit of the laziness of a home craftsman, so I implemented the simplest design that provides secure fixation and smooth adjustment of the string height during cutting above the surface of the base of the machine.

The ends of the nichrome wire are attached to the springs, dressed on M4 screws. The screws themselves are screwed into metal racks pressed into the base of the machine. With a base thickness of 18 mm, I picked up a metal stand with a length of 28 mm, so that when fully screwed in, the screw does not extend beyond the bottom side of the base, and when the maximum unscrewed state provides a foam cutting thickness of 50 mm. If you need to cut sheets of foam or foam rubber of greater thickness, then it will be enough to replace the screws with longer ones.

To press the rack into the base, first a hole is drilled in it, with a diameter of 0.5 mm less than the outer diameter of the rack. In order for the racks to be easily hammered into the base, the sharp edges from the ends were removed on an emery column.

Before screwing the screw into the rack, a groove was machined at its head so that the nichrome wire could not move arbitrarily during adjustment, but occupied the required position.

To make a groove in a screw, first its thread must be protected from deformation by putting on a plastic tube or wrapping it with thick paper. Then clamp the drill in the chuck, turn on the drill and attach a narrow file. In a minute, the groove will be ready.

To prevent sagging of the nichrome wire due to elongation when heated, it is fixed to the screws through springs.

A suitable spring from a computer monitor, used to tension the ground wires on the kinescope, turned out to be suitable. The spring was longer than required, I had to make two of it, for each side of the wire attachment.

After preparing all the fasteners, you can fix the nichrome wire. Since the current consumed during operation is significant, about 10 A, for reliable contact of the current-carrying wire with nichrome wire, I used the method of fastening by twisting with compression. Thickness copper wire at a current of 10 A, it is necessary to take a cross section of at least 1.45 mm 2. You can select the wire section for connecting nichrome wire from the table. I had a wire with a cross section of about 1 mm 2 at my disposal. Therefore, each of the wires had to be made of two with a cross section of 1 mm 2 connected in parallel.

If the electrical parameters of the nichrome wire are not known, then you must first try to connect a low-power electrical appliance, for example, a 200 W electric light bulb (a current of about 1 A will flow), then a 1 kW (4.5 A) heater, and so increase the power of the connected devices until the nichrome the torch wire does not reach the correct temperature. Electrical appliances can also be connected in parallel.

The disadvantages of the last scheme for connecting a nichrome spiral include the need to determine the phase for correct connection and low efficiency (coefficient of performance), kilowatts of electricity will be spent uselessly.

Styrofoam (extruded polystyrene foam) is used as thermal insulation for external and interior decoration, used for packaging goods or manufacturing prefabricated structures. The material is produced in the form of sheets, which are cut on the spot and adjusted to the dimensions of the surfaces. For quick cutting of foam, you will need a special device that allows you to make a straight or curly cut.

Manual processing of foam plastic is possible at home and in small workshops using a simple device assembled from improvised materials. Extruded polystyrene foam has a fairly dense structure, so you can cut the plates with a metal tool heated to a certain temperature. As a cutting surface, a wire that supplies electric current is suitable, with the supply of which the main difficulty in assembly is associated.

A self-made machine allows you to get tiles or bars from ordinary foam for packaging suitable thickness with their further application in certain structures. With such a device, you can also cut foam rubber or similar materials that are needed for the manufacture or repair upholstered furniture. The compact dimensions of the device for cutting polystyrene with your own hands using nichrome allow you to install the machine in a small workshop or even on a balcony.

To cut foam at home, you will need a structure that can be assembled from simple materials available at any hardware store. First you need to determine the parameters of each element, taking into account the dimensions of the foam plates that will have to be processed . In most cases, the following details will suffice:

The basis from dense plywood, a chipboard or the massif. You can order new parts or use items old furniture(doors, walls, shelves). A base of 400 x 600 mm is sufficient for working with foam.
A string or wire in the form of a thermal knife for polystyrene.
Metal posts, screws, springs or ordinary nails to fix the wire. The installation height of the cutter depends on the expected thickness of the finished boards.
Fixings for parts on the base. A few self-tapping screws are enough to fix the structural elements.

To assemble a thermal cutter, it will take up to one hour of working time. Each of the structural elements can be quickly replaced in the process of repair or expansion of the fixture.

Action algorithm

To make a device for cutting foam or similar materials, you need the most common tools (hammer, screwdriver, pliers). You can work anywhere with enough space (balcony, room, hallway, garage, etc.). No involvement of assistants or third-party specialists is required.

Assembly is carried out in the following order:

Legs can be attached to the base, which will increase stability when cutting foam with a string.

How to choose cutting wire

A suitable cutter can be made from nichrome wire (X20H80), which is used in the design of most household appliances as a heating element. In terms of mechanical characteristics, nichrome is comparable to ordinary steel, while it has a high resistivity and a heating limit up to temperatures of +1200 ºC. Wire diameters up to 10 mm are available for the manufacture of cutting fixtures.

Precise and smooth foam carving is possible when the cutting line is heated to a temperature that is two to three times the melting threshold (+270 ºC). It should be borne in mind that such a process involves the consumption of energy and the absorption of heat by the material itself in proportion to its density. Therefore, for efficient and safe cutting, it is necessary to select a wire of suitable thickness in order to exclude metal melting at maximum heating.

Calculation and preparation of the electrical part

For the safe operation of the device, it is necessary to correctly mount the conductive elements that are connected to the power source through the captive terminals. To cut material, you can use a variable or D.C.. The power of the source is calculated based on the fact that up to 2.5 W will be needed for effective cutting of 10 mm wire (for 500 mm - 125 V).

The voltage is proportional to the resistance and is calculated using formulas or tables. But on average, with a wire diameter of 0.8 mm, a length of 500 mm and a resistance of 2.2 ohms, you will need a 12 V current source with a load current of 12 A. Changing the length up or down will require a similar increase or decrease in voltage at the same strength current.

Power sources and connection diagram

Safe cutting is ensured by connecting to a regular 220 V household network through a car transformer. To adjust the voltage in a single primary winding, a handle is provided, with which the graphite wheel is moved and the voltage is removed from the corresponding section. This parameter can be changed within the range from 0 to 240 V. Connection to the current source is carried out through the terminal box.

When connecting a homemade foam cutting machine to the mains, you need to make sure that the phase does not fall on a common wire. All the necessary parameters and connection diagram can be found on the transformer housing. Before connecting to the network, you need to check the operation of the device using a multimeter.

A simpler option for supplying current to the wire is to use conventional step-down transformers with taps from the secondary windings. In this case you don't have to adjust the voltage, since this value is always constant and sufficient to heat the wire to the desired temperature. You can select the desired value during the initial setup of the transformer, providing a certain number of turns of windings in the circuit.

You can also heat the wire for cutting polystyrene using household appliances. In this case, the following nuances are taken into account:

It must be taken into account that the cutting tool will immediately be hot when energized, so it should not be touched to check the temperature.

To make a thermal knife for polystyrene or foam rubber, it will not take a significant investment of time and effort. For this, a wire of almost any diameter is suitable, but with unknown parameters (diameter, resistance), you need to increase the power gradually, connecting first low-power current sources. Great importance has reliable isolation of contacts and phase position control, which cannot be connected to the wire.

Styrofoam rightfully occupies a worthy place in construction and finishing works. Its heat-insulating and noise-absorbing characteristics allow it to be used in the decoration of facades, country houses, industrial enterprises. The construction of the material consists of foam particles that fill the gas cavity during molding. The cost of the material is not high, it can be used in any field of activity, large letters on advertising, information boards, etc.

Basic Methods for Cutting Styrofoam

Most the best option The thermal insulation of the building is polystyrene foam. Usually, a non-dense structure is chosen for these purposes, due to the low cost. This causes inconvenience when cutting, the structure of the cells crumbles, and with a little effort, you can break the structure with your hands. The foam cutting tool has various modifications, ready-made options are sold, you can also make a design with your own hands.

It is important to understand that the structure of the foam is categorically related to the impact of certain liquids. Acetone or gasoline destroys the structure of the foam, the product will have to be made again. Temperature operation modes are no more than 50 °.

Cutting foam at home is performed by many improvised tools. For example, when working with small workpieces, the most in a simple way is to use a utility knife. The process is inaccurate, because the blade dulls quickly, for better processing the knife can be heated.

Each of the devices has advantages and disadvantages; before cutting with your own hands, it is important to note the characteristics of the foam, to choose a tool for cutting the foam to size.

In hardware stores you can buy a special tool - a knife with a heated blade. Work with this device is carried out on its own, in order to avoid slipping and injury. The main disadvantages of a cutting knife are that they can cut material of a certain thickness; for smooth work, you need to correctly mark the product and spend time on it.
A type of heated knife can be a soldering iron with a special nozzle. It has a higher heating temperature, you need to be careful when working, a molten drop does not deliver joyful sensations when it hits the skin.
A shoe knife for cutting foam is used with a long blade up to 40 cm. The tip of the knife remains blunt, and the wide blade must be perfectly sharpened. Adjustment and sharpening is carried out every 2 meters of the cut product. The process will be accompanied by a squeal, you can eliminate unpleasant sounds by using headphones.
Thicker pieces can be cut with a fine-toothed wood saw. The lower the level of the teeth, the better quality output part, however, scuffs and bevels will still be present. The method does not require an application special products, often used for long straight cuts of foam.
The most popular way is to cut the foam with a string. The performance of this method is equivalent to industrial equipment, it is enough to build a small structure. The string is used when working with foam plastic of various grain sizes and densities.

Some cases, in the absence of any of the above from cutting tools requires electrical intervention. The grinder is used with a disc of minimum thickness. The work implies the presence of increased noise, debris from foam particles throughout the territory.

The processes of work on the insulation of one dwelling can be performed with a manual type tool. The wire for influencing the foam is used on a special stand, previously prepared. The design consists of nichrome wire, easily made by hand. The connection diagram consists of two fasteners, a load for tension and power to the network. In cases where production volumes are increased, special foam processing machines are used.

You can buy them in specialized stores, as well as make your own.

Machine classification

The design features of the units do not differ from each other. In each of them, cutting occurs due to a heated wire fixed in a certain position. Some of the modifications have up to six adjustable strings, this allows for more massive work. Foam cutting machines can be with turntable, permanently fixed cutting element.

Devices are divided into several categories:

software-controlled equipment that allows you to cut figures of increased complexity;
portable cutting elements;
transverse or horizontal types of cutting.

The most complex machines in design allow you to work on several planes of the product at once. The performance of foam cutting machines is designed for industrial purposes; in one go, some models can process over 10 meters.

Do-it-yourself foam cutting tools

Home insulation materials are always available for sale. It is best to glue the foam on a flat wall, but if protrusions are found, you will have to adjust the shape of the foam. Styrofoam cutting is carried out both by purchased equipment and by self-made.

To build a structure, it is important to select the parameters and drawings. The type of work also depends on the design and its dimensions. Cutting foam at home is carried out from improvised means, the main thing is to choose the right materials. It is important to comply with safety requirements, when cutting, slippage of the product, damage to the limbs is possible.

In the process of heating the foam, fumes are released, if inhaled, they can damage the mucous system of the worker.

Homemade thermal cutting knife

It is possible to correct the shape of insulation products, cut out small products and blanks with a thermal knife. To cut foam you will need:

A krone-type battery with an output voltage of 9 volts, or a set of finger products.
The nichrome fishing line is stretched between the plates, the length is not more than 10 cm.
Several wires connect the ends of the wires to the battery.

The simplest cutter can be assembled from improvised means, it will help to chamfer corners, perform the necessary fitting of polypropylene parts. It is necessary to install a power button that will activate the device, this is done for convenient, safe operation.

DIY nichrome cutter

Do-it-yourself production implies the presence of certain means. In order to qualitatively assemble a tool for cutting foam, you will need:

nichrome wire, it can be purchased at radio parts stores of the required size;
12 volt step-down transformer, it is a computer power supply or Charger car battery;
long needle;
rheostat, which makes it possible to regulate the strength of the current;
electrical wires suitable for connection are long.

The device can be mobile or fixed on a table. The frame is made of wood, the wire is set to a height of 10-15 cm, on the adjusting screws. The screws that secure the nichrome wire must be of the right length to adjust the height to the desired level. A weight is suspended from one side of the screw to tension the wire for a straight cut level.

The impact of current leads to splitting of the wire, the foam is easily exposed to temperature effects. The edges are sealed, this prevents the decay of the structure of the material. The cutting of the foam begins after the appearance of a red tint on the wire, it is not necessary to bring the incandescence to a high level, in these cases the width of the cut will be too large.

When performing the procedure, you should use the means personal protection, mask, gloves. The melting process releases toxic fumes.

Cutting is done indoors with good ventilation or outdoors.

Design features and principle of operation

The string expands when heated, adds up to 3% in length, cutting with a sagging cutter will not be of high quality, so a special mechanism is added to the design. With actions with a low frequency, it is possible to use a spring, it will gradually stretch the wire to the desired state. Mass use means fast stretching, so it's best to use a suspended weight to one side of the string.

The foam cutter is powered by power sources with an output voltage of 12 to 36 volts. Most good option a laboratory transformer can be distinguished. The device is able to withstand high loads, to smoothly adjust the output voltage.

Specialized machines and their prices

The manufactured machines are delivered for mass production. There are modifications with six cutting elements, which allows you to quickly cut a large amount of foam in one run. Laser machines perform work for architectural purposes, are able to cut various shapes, materials in thickness.

Machines have excellent characteristics, can have the functions of simultaneous processing of many elements, and have high productivity. The price of devices is high, you need to know exactly what the cutter is used for.

Frp 01

A simple design allows you to modify the device for various shapes and sizes of foam blanks. Styrofoam cutting tools various types allow you to take a number of actions. Implemented the ability to trim linear parts, curly elements, insulation boards and signboards.

The cutting is done by the machine by connecting to the CNC. The cutting program is supplied with various settings. The price of such a device starts from 110 thousand rubles, it is important to check the functionality and reliability of the design before buying.

SRP "Kontur"

There are modifications of machines for the production of elements of various shapes. Styrofoam cutting machine is manually operated, has simple design rich functionality. The power consumption is not high, the components are collapsible, which allows you not to worry about transportation.

The cost of equipment starts from 40 thousand rubles. The main difference between market models and hand-made ones is the tests carried out for the safety and reliability of parts.

Self-made cutting machine

A complete machine can be made at home. For the manufacture of the machine, a tabletop and a frame of the desired width, as well as other details, are selected. A do-it-yourself foam cutting machine is made from improvised means, by analogy with the smallest nichrome modification. There are several modifications and structures of machines, implemented in accordance with the conditions of the details.

Manual cutting of styrofoam

Of all the above methods, manual cutting of foam is not so expensive, an abundance of methods allows you to influence foam products in accordance with the tasks.

The simplest and least expensive way is cutting with large sharpened knives. The tip of the knife is left blunt, oil must be distributed across the width of the knife for lubrication, the speed of this method is not high, cutting of small volumes is used.
A hot rune allows you to quickly perform work, but is harmful to health.
Cold wire cutting is similar to the action of a saw, it is only necessary to make a productive structure.
Cutting with a hacksaw blade.

Professional methods involve the use of a ready-made tool. High-quality and fast cutting is carried out by using suitable devices.

Homemade machine on the table

If there is a large table and workplace, this will save a lot of time and effort, because when applying manual methods material crumbles, deteriorates. Homemade machine and its foam cutting design is done by using nichrome string.

A suitable power source is used, which produces from 12 to 36 volts. It is possible to use the voltage of a regular network, but only there is a wire coated with nickel, this method causes an electric shock, which is significantly felt by a person.

The machine for figured cutting of polyfoam

Complex geometric figures can be processed with a special machine. The device allows you to make figured cutting of foam plastic with your own hands. The design is carried out according to the same principles, only the nichrome wire is stretched vertically.

The fastening mechanism fits on one side, which makes it possible to move the product on the table top.