CNC Hot-Wire Cutter Gives Form To Foam

Rapid prototyping tools are sometimes the difference between a project getting off the ground and one that stays strictly on paper. A lightweight, easy-to-form material is often all that’s needed to visualize a design and make a quick judgment on how to proceed. Polymeric foams excel in such applications, and a CNC hot-wire foam cutter is a tool that makes dealing with them quick and easy.

We’re used to seeing CNC machines where a lot of time and expense are put into making the frame as strong and rigid as possible. But [HowToMechatronics] knew that the polystyrene foam blocks he’d be using would easily yield to a hot nichrome wire, minimizing the cutting forces and the need for a stout frame. But the aluminum extrusions, 3D-printed connectors. and linear bearings he used still make for a frame stiff enough to give clean, accurate cuts. The addition of a turntable to the bed is a nice touch, turning the tool into a 2.5D machine. The video below details the construction and goes into depth on the toolchain [HowToMechatronics] used to go from design to G-code, including the tricks he used for making a continuous path, as well as integrating the turntable to make three-dimensional designs.

Plenty of hot-wire foam cutters have graced our pages before, everything from tiny hand-held cutters to a hot-wire “table saw” for foam. We like the effort put into this one, though, and the possibilities it opens up.

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Minicut2d And Omniwheel Robot

You’d think we would be done with the World Maker Faire posts by now, but no! We keep looking at our memory cards and finding more awesome projects to write about.

[Renaud Iltis] flew over from France to show off MiniCut2D, his CNC hot wire foam cutter. MiniCut2D uses X and Y, and Z stMINICUT2epper motors much like a 3D printer. Rather than print though, it pulls a heated nichrome wire through styrofoam. Foam cutting is great for crafts, but it really takes off when used for R/C aircraft. [Renaud] was cutting some models out of Depron foam in his booth. [Renaud] has set up FrenchFoam.com as a central location for users to upload and share designs in DXF format.

One of the neater features of MiniCut2D is that it can be loaded with a stack of foam boards to make several cuts at once. Not only is this a time saver when cutting repeating designs like wing ribs, but it also ensures the cut pieces are identical. Hey, even CNCs make mistakes once in a while.

 Omniwheel Robot

vic

In the MakerShed booth, we found [Victor Aprea] showing off Wicked Device’s new product, the Omniwheel Robot. Omniwheel utilizes a holonomic drive with omnidirectional wheels. The kit comes with a Nanode Zero, Wicked Devices’ own Arduino Uno clone, a motor control board, 3 motors, 3 omnidirectional wheels, and a whole list of hardware. The only thing needed to complete the kit is a radio control unit and receiver. Omniwheel may be simple, but we found driving it around to be mesmerizing – and a bit challenging. It’s a good thing [Victor] brought that plexiglass cover, as we bumped it a few times.

We’d love to see one of these little bots with a couple of sensors and autonomous control. If you build one, make sure to post it to Hackaday.io!