There are a million things you can do with foam, from some very impressive RC airplanes, all the way up to full-scale planes you can fly off into the wild blue yonder. Cutting foam, though, that’s a problem, and your best option is usually a hot wire foam cutter. [Darcy] put up some plans for a very nice bow cutter, but there’s also some experimentation for a foam slicer – a hot wire machine that takes a foam part and slices it like a smokehouse ham.
The bow-style cutter features laser cut parts, a pair of 1/4-20 bolts, a power supply, and about a foot of nichrome wire. It’s the bare minimum for cutting foam, but it seems to work really, really well.
The hot wire foam slicer is a much more interesting contraption, capable of making multiple thin sheets out of foam. Basically, it’s a laser cut tray with a bolt hole pattern running along the sides. Put two bolts along the side, loop some nichrome wire around the screw flights, and you have a way to cut foam in thicknesses of about 1/20th of an inch. Great if you’re trying to skin a model in very thin depron, or you just can’t find the right thickness of foam for your project.