Hot Wire Foam Cutter

Small machine to cut foam, styrofoam or similar materials


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This is a small Hot Wire Foam Cutter I designed. As some of you requested in the video of the build I'm posting the STL files so you can build it too. Important: You will need some extra materials and basic tools. This is not entirely made of plastic. Also don't use heat sensitive filaments (PLA or similar).

Materials and methods

Required parts:

1 x 8 mm round aluminum tube.
1 x 10 x 12 mm rectangular aluminum tube.
1 x 0.25 mm nichrome wire.
12 x 8 mm round adhesive bumpers.
1 x 3mm round metal spike
4 x M3 x 8 mm flat screws.
6 x M3 x 14 mm countersunk screws.
1 x M3 x 10 mm flat screw.
2 x M3 nuts.
1 x M3 wing nut.
1 x M3 x 16 mm flat screw.
1 x M3 x 20 mm countersunk screw.
2 x M4 x 40 mm hexagonal screws.
1 x M3 x 5 mm grub screw.
5 x M4 nuts.
2 x M4 washers.
1 x M5 washer (15 mm outer diameter).
1 x M4 wing nut.
1 x female 12 mm 12 V socket.
12 V DC Motor Speed Controller.
12 V DC PSU (3 A).
Some medium gauge wire.
Zip ties.
Electrical terminals.

This is the exact speed controller I used:

Also this is the tool I used to bend the aluminum tube:



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36a43105298ae6c2186214e8a30eab9c?default=blank&size=40Eli Silverman added this to the D&D Crafts collection ago
Ebf1a0296bf9a5205d4771ae1c939c2b?default=blank&size=40Angie Rigby added this to the Stuff collection ago
00edd7728fc64463beba4444c6c1d869?default=blank&size=40Yves Fels added this to the DIVERS collection ago
Dfd63ddaac6cfab93f8de2fb875a2aa7?default=blank&size=40agering added this to the Meins collection ago
Mini elite worm white background v2Elite Worm published this design ago