Cheap, dirty and perfect V-Groove Foam Cutter

If the only tool you have is a hammer, everything looks like a nail. Conversely, if you have the right tool for every job, it makes the difference between pro and amateur. [ftregan] needs to cut perfect V-grooves in foam for many of his projects, especially building RC planes. He wasn’t too satisfied with the results using his Xacto knife. And a proper tool was going to set him back by almost $25, but following that example he built his own version of the tool for much less.

Two pieces of wood cut at a 45 degree angle are held between two flat support pieces. A pair of regular shaving blades form the cutting elements. While it looks simple, it’s important to get the angles and blade directions correct. A central wooden wedge holds the two blades in place. He also added a small guide marker that let’s you cut precise straight grooves. [ftregan] built the tool to allow cutting 6mm thick foam but given that it’s so quick and cheap to build, we guess it’s easy to make a few of these to allow cutting different thicknesses of foam. We’re sure that many of you will find different or better ways of doing this, but considering [ftregan] spent just 15 minutes cooking this up, it’s not too bad, especially since the results are mighty good.

Another method of cutting foam is with hot wire. Check out this DIY Foam Cutter that we featured earlier.

Not Having The Room Isn’t A Good Reason To Not Have A CNC Router Anymore

PhlatPrinter CNC Machine

Typically, CNC Machines take up a larger footprint than that of the raw material it is cutting. The size of such a machine may have prevented interested makers/hackers from buying or building one for themselves. If you are one of those people then you’d be interested in [Fly3DMon’s] series of CNC Router projects called PhlatPrinter.

A typical CNC Router has a bed that the work piece is mounted to and that work piece stays stationary. The tool then moves in 3 axes, removing material, leaving behind a finished part. The PhlatPrinter works more like a large format plotter, where the work piece is moved back and forth via rollers while the tool only moves in 2 directions. What this allows is a CNC Machine that takes up very little floor space when not in use that can handle any length of material!

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DIY Foam Cutter Makes it Too Easy

Cutting foam is pretty tricky without a hot wire cutter. Don’t have one? Well, lucky for you, [Darcy Whyte] has a guide on how to make one. It takes just over an hour to build, and it costs next to nothing in supplies!

[Darcy] is using an old 9V power wart that he had lying around, but you can probably use any DC power supply. He designed the frame in SketchUp and cut it out with his CNC router, although a saw will work just as well for MDF. A piece of 40 gauge nickel chromium wire was strung taught between two 1/4-20 bolts, with one held back by a spring. The spring acts as a safeguard to prevent snapping the wire during overly aggressive cuts. This may be a simple build, but it does produce a handy tool.

[Darcy] demonstrates cutting foam with his creation in a video after the break. We think he could cut thin plastic with it as well—modify your 3D prints, anyone?—though he may need to crank up the voltage a bit.

Continue reading “DIY Foam Cutter Makes it Too Easy”