How is foam cut? Cutter for foam plastic from improvised materials How to cut foam plastic with nichrome wire 12v

Standard construction has long since sunk into oblivion. This is noticeable when visiting low-rise construction zones. Each house is individual, unique. But each household requires insulation, if it was not provided during the construction process. It is unlikely that foam manufacturers will produce boards customized size for small orders. You'll have to cut. But how to cut the foam when installing the thermal insulation of the building with your own hands?

Foamed polystyrene foam is easy to process by cutting. Before cutting foam at home, you need to decide on the required accuracy and cleanliness of the cut. After that, select the necessary device for cutting foam plastic from the following:

• saw (hacksaw);
• string;
• thermal cutter;

There is no single answer to the question: “What is the best way to cut?” until there is no certainty on the volume and linear dimensions processed parts.

Foam plastic milling is not carried out due to the extremely low mechanical stability of the material.

Just cutting

When carrying out work on the insulation of the foundation, underground utilities, ceilings for screed, facade for plaster, special accuracy and evenness of the cut is not much needed. Especially if the building has a simple facade configuration. In this case, you can use hand tool for cutting foam: knife, hacksaw, metal string.

Their use will lead to the loss of granules at the cut boundary and the formation of an uneven edge. The presence of a loose fit of the plates can be leveled by filling the voids with mounting foam.

Rectilinear cutting with a knife with small notches is justified with a material thickness of 50 mm, a hacksaw can cut insulation up to 250 mm thick. You can use a serrated kitchen knife to cut the styrofoam. A hacksaw with a small tooth is purchased at a hardware store.

For the convenience of using a string for cutting foam (you can use old strings, for example, from a guitar with a spiral winding), we install at its ends wooden handles. They cut the insulation with reciprocating movements, as if they were using a two-handed saw. Large slabs can be cut by two people. In this case, the sheet to be cut must be fixed.

Before cutting the foam, the cutting edges must be treated with a liquid lubricant. This will create a certain comfort during work (improve slip, reduce noise).

Figured carving on foam using this tool is extremely difficult.

Using a thermal knife

Do-it-yourself cutting of polystyrene with the use of a thermal knife is justified with a plate thickness of up to 50 mm. To cut off a piece of polystyrene, a hot knife is advanced with average speed, which ensures the quality of the cut without tearing out fragments and melting the edges.

Purchasing a longer blade for this appliance is not entirely beneficial. With manual cutting, it is impossible to cut strictly perpendicular to the surface. The end of the sheet will have a bevel, which is extremely inconvenient during installation. In order to better cut a thick sheet, it is necessary to cut from both sides, deepening the hot knife by half the thickness or a little more.

We manufacture and use a thermal cutter

For cutting polystyrene with your own hands, devices with a thin hot element are most often used. General principle the actions of any thermal cutter for foam plastic are one.

The heated element separates the material with subsequent sealing of the opened volumes. Using thermal cutters for foam plastic, we get a perfectly smooth cut, which is very important for high-quality insulation work.

The purchase of a factory-made foam cutting machine is not economically feasible.

Only if it is not decided to do it professionally and permanently. In most cases, when cutting curly elements is not required, you can use homemade cutter for foam.

Making a foam cutter with your own hands is quite simple and quite inexpensive. After completion of work, it will not lie dead weight, take up space. It can be assembled and disassembled as needed. If not needed, its components can be used for other purposes.

Before you make a foam cutter, you need to prepare everything you need:

• blank for the working surface;
• nichrome wire;
• laboratory adjustable transformer (LATR);

Chrome-plated nichrome wire can be used without a step-down transformer, but this increases the risk of electric shock.

• electric wire, mount for it,
• springs for thread tension;
• adjustment mechanism.

When manufacturing and using the device, follow the rules for the design and operation of electrical installations.

To make equipment for cutting foam, start by marking and trimming the working surface. Determine its geometric dimensions in accordance with the dimensions of the cut plates. It is better if the table surface is larger than the sheet area.

We install racks (supports) with the possibility of adjustment. This may require a small tool in the form of hex bushings with internal thread. They will make it easier to adjust the cutting height. The cutting wire is tensioned with springs. We lay and fix an electric wire on different sides of the thread. We connect the other end of the cable to LATR (if there is no LATR, it can be replaced using an autotransformer to charge the car's batteries). The device is ready to work.

Cutting foam at home must be carried out in compliance with safety measures. During heat treatment, toxic fumes are released. Therefore, we cut out parts from foam either on the street, or use respiratory protection at a workplace equipped with exhaust ventilation.

The use of such a device for cutting foam allows you to speed up the process of preparing insulation fragments as much as possible.

We use automated systems

sophistication architectural design also require insulation. In order to preserve their expressiveness, it becomes necessary to manufacture complex elements. How to cut out such details? More affordable option- processing of a heater by milling. But foam plastic milling is not carried out for the reason that the cutter pulls out large enough pieces of material during its rotation.

Dense polystyrene foam has a higher mechanical strength and is well milled. Anything is made from it: a letter, a number, a graphic element of any complexity. At least a hedgehog. It is recommended to cut penoplex at high angular speeds with an average linear feed. To install the fabricated fragments on the facade, ceresite is used.

Foam laser cutting is the most advanced technology that combines a hot cutting tool and the precision of an automated system. Laser cutting of foam allows you to produce parts of any complexity with the highest precision with a minimum level of waste. Foam laser cutting provides a completely smooth cut surface using a hot beam of directional light moving at high speed. For him, there are no restrictions on the thickness of the material and the complexity of the element.

The choice of cutting equipment used for foam boards and for extruded polystyrene foam should be conscious. Meet the technological requirements for finished products and be economically justified.

Among the many types building materials foam plastic rightfully occupies a worthy place - a universal remedy with special heat-insulating and sound-absorbing properties. The production technology of this material involves the use of foamed plastics in the form of often located gas cavities. Styrofoam has a fairly low cost, which allows you to make its purchases in the quantity that is necessary to complete a particular task. This material is widely used not only as a heat-insulating material, but also in design and advertising, where three-dimensional figures are cut out of it. The article will focus on cutting foam at home.

The main advantages of using foam

This is one of the best materials for the implementation of thermal insulation of the building, both from the outside and from the inside;

• can be used as an additional layer of sealing when transporting any items;
• manufacturers of decorative products for repair work in a wide range represent ceiling coverings that differ not only in color, but also in texture;
• unique means of soundproofing, as private rooms, and the entire structure;
• is an environmentally friendly material, since it does not contain toxic components;
• is resistant to various microorganisms, fungi, mold, etc.;
• due to the low weight of the product, installation will not be difficult. Transportation, reloading, as well as laying is carried out without much effort.

Despite all its positive aspects, working with polystyrene provides for compliance with the nuances of operating this material. Many technical liquids, such as acetone, white spirit, gasoline, etc., act destructively on the foam. An important point is compliance temperature regime in places where this type of insulation is used. When the air temperature exceeds +500C, there is a possibility of a destructive process of the internal structure of the foam boards and their crumbling.

Varieties of foam

To date, there are several brands of foam, which is indicated by special markings. PSB-S - bespressovy self-extinguishing foam.

A clear idea and understanding of the meaning of a certain set of numbers and letters will allow you to choose exactly the material that will best meet the requirements of further use:

• PSB-S-15- has a low density index and is traditionally used as a heater in places where no mechanical load is expected. Moisture resistant and fireproof. It is possible to carry out thermal insulation of containers, wagons, mansards. This brand is not suitable for curly cutting foam;
• PSB-S-25- universal brand, which is a priority. Widely used for wall insulation both inside and outside. Practical, durable, environmentally friendly;
• PSB-S-35- an insulating agent for the foundation or communications underground. Quite often used in the process of arranging the pool, sports grounds, lawns. Resistant to moisture, the development of fungi and microorganisms, resistant to mechanical stress;
• PSB-S-50- the density of the material is very high, which indicates the possibility of using it as an option for insulating floors in multi-storey buildings, garages. Moisture resistant, fireproof, durable. Perfect for artistic cutting and use both indoors and outdoors.

The Importance of Styrofoam Density

• The density of any material indicates that the product has a high resistance to various mechanical stresses. Polyfoam is no exception. There is a certain pattern - the higher the density index, the greater the weight of the material. This, in turn, determines the possibility of using foam plastic in certain conditions, since the installation process plays an important role in choosing a material brand.
• Dense foam is able to withstand loads and at the same time provide thermal insulation of the space. Resistance to the appearance of various fungi, mold and other microorganisms makes it possible to use this material in special conditions. The strength index of the foam has a direct impact on the pricing of this material.
• The low density also indicates that when cutting such foam, it will begin to crumble and it will not be possible to make clear shapes with sharp contours from it.

Foam application

This material is widely used not only in construction, but also:

• as packaging material in medicine;
• as one of the means of ensuring safety in open water (buoys, floats, vest fillers, life buoys, etc.);
• at the stage of repair of refrigerators and other climatic equipment;
• in shipbuilding as an unsinkable means (on large and small ships);
• to implement design ideas when decorating the interior of the exterior;
• in advertising (volumetric letters).

Styrofoam is commercially available in the form of sheets of a certain thickness. In the process of its fastening, it is often necessary to cut it into smaller segments. The implementation of this task is not as simple as it might seem at first glance. Cutting foam has a number of tricks and nuances, the observance of which will allow you to make machining material in a short period of time.

Styrofoam cutting tools

Quite often the question arises "what is the best way to cut foam at home." In fact, there are several ways to perform this process. Elements are modeled using the following tools:

• sharp knife with a rubber tip;
• soldering iron with a special tool - a knife attachment;
• wood saw;
• string, etc.

Each method has both disadvantages and advantages. Let's consider them in more detail.

• Styrofoam cutting knife must be very sharp. It is suitable for working with small dimensions of the material, however, a rubber nozzle should be located at the end of the cutting object. Before starting the cutting process, it is desirable to fix the workpiece in a vice or other device. The movement of the knife should have a direction “away from you”, since the possibility of it slipping is not excluded, which in turn can lead to a traumatic consequence for the master.

• For the manufacture of foam parts, where special cutting accuracy is required, you can use soldering iron, which is equipped with a special nozzle - a knife. During the operation of the soldering iron, the nozzle gradually heats up. It remains only to move the device along the surface of the foam with smooth, unhurried movements. However, you should be extremely careful, because in the process of cutting under the action of high temperatures the plastic starts to melt. As a result, a hot drop of plastic mass can get on the skin or clothing. To avoid such a nuisance, it is important to secure your movements.
• Ordinary shoe knife can cut a sheet of foam up to 40 cm thick. At the same time, a wide blade must be strongly sharpened, and the point must remain blunt. Every 1.5 - 2 m, the knife must be sharpened. Therefore, the grindstone should always be nearby. Of course, the cutting process will be accompanied by a specific sound - a “squeal”. But this can be eliminated by wearing regular headphones.
• If you need to cut foam sheets with a thickness of more than 80 cm, then you need to pick up wood saw with fine teeth. This is very important, since the accuracy and uniformity of the cutting depends on the size of the teeth. In this case, you will not have to make special efforts. At the same time, injuries are minimized. However, this method is relevant if it is necessary to perform a long straight incision.
• With a slight thickness of the material it is possible to use for cutting regular utility knife. However, despite the fact that this tool is quite sharp, it also tends to become dull over time. It would be nice to slightly heat the knife so that the cutting process runs more smoothly.

• Cutting Styrofoam with a String- the most popular way at home. The performance of this process is quite high. However, it is necessary to build special device, the location of which must be stationary. The accuracy of cutting and the speed of the process is equal to the production ones.
• In some cases, you can even use grinder for cutting foam. However, the disc should be selected for metal of minimum thickness. At the same time, the work is accompanied by noise not only from the foam, but also from the functioning of the tool. And the debris will fly in all directions.

Foam laser cutting

• It is possible to cut foam plastic into segments of the required size not only when carrying out thermal insulation work, but also to create special architectural elements of various sizes and configurations. On an industrial scale, to create three-dimensional figures, laser cutting of foam is used, which functions thanks to special software. Moreover, thanks to the use of a laser, three-dimensional cutting can be performed. As a result, unique figures with a processed inner and outer surface are obtained quite quickly and efficiently.

They are used in the following industries:

• in metallurgy (for casting metal alloys);
• automotive industry (car tuning);
• construction (for the construction of formwork, thermal insulation of buildings and pipes, various architectural forms);
• advertising (logos, etc.);
• theatrical decoration.

This is just a small list of where foam or foam products can be used. For the production of elements by the method of figured cutting, it is important to ensure the equipment is correct. software, as well as to automate the process of supplying raw materials to the maximum. According to the sketch stored in the computer's memory, you can perform any foam cutting action, regardless of the complexity of the project.

• To minimize waste when cutting foam, it is important to accurately calculate everything and make a layout with maximum accuracy. It is the quality of the initial workpiece that affects the final result. Therefore, foam sheets must have a perfectly flat surface.
• A sheet of material placed on a foam plastic shape cutting machine is fed very slowly and prudently for processing. Therefore, to fulfill the order, it is supposed to involve simultaneously several trained specialists who have the skills to work with similar materials.
• Do not forget about the golden rule "Measure seven times and cut only once." Since the foam crumbles during the cutting process, before cutting out the desired element, repeatedly check that the dimensions applied correspond to the desired format.

Making a do-it-yourself foam cutting device

In order to build an apparatus that cuts foam with maximum efficiency, you must have:

• long knitting needle;
• nichrome wire;
• step-down transformer (12 - 24 Volts);
• rheostat, which can be adjusted if necessary;
• electrical wires.

• Under the influence of current, the nichrome is heated, as a result of which it is possible to cut the foam with ease. In the process of cutting with nichrome, the edges of the cut are sealed, preventing the destruction of the material.
• You can start cutting the foam after the wire has heated up to a reddish state. It is unacceptable to bring excessive heat, as the cut will be too wide. Moreover, it should be noted that the heated wire tends to stretch. This indicates the need for a strong spring in this device.

Precaution! It is important to follow basic safety rules when cutting polystyrene using the nichrome method, since this material emits toxic fumes when heated. Make sure you have a protective mask for the procedure. It is advisable to carry out all work in a room that is well ventilated.

Styrofoam cutting video

Styrofoam is a lightweight, durable, good heat-insulating material that is very easy to work with. But it has one unpleasant feature: it is usually made in the form of slabs large sizes, which in the process of work have to be cut into pieces of smaller sizes. No matter how sharp the knife and saw are sharpened, they will not be able to cut the plate neatly, because the structure of the foam is destroyed by mechanical action, which is why it does not cut, but crumbles. Therefore, for cutting, you need to use a special foam cutter.

Styrofoam, like any material, requires cutting, this is why you need a cutter.

The simplest homemade foam cutter

Such a cutter is not difficult to make with your own hands. To do this, just take the thinnest guitar string and 4-5 big batteries for an electric flashlight. Having connected all the batteries in series into a single element, you need to connect and fix the guitar string with electrical tape to its ends, closing the electric arc. Due to the electric current passing through the string, the string will heat up.

Image 1. Diagram of a cutter that allows you to cut flat sheets from a block of foam.

At the point of contact with a string heated to the desired temperature, the foam sheet will instantly melt, dividing into two halves, the cut of which will turn out to be fused and even. But for normal cutting, the string must be heated to a temperature of at least 120-150º. When working, it will not be difficult to determine whether the string has warmed up enough, since when cutting the foam plastic, small sticky pieces will remain on the string. The longer such pieces remain, the lower the temperature of the string. But if they do not remain on the string at all, then this means that this kind of thermal knife is heated more than necessary.

Such a primitive foam cutter is able to easily cut 2-3 large layers of material. But with large volumes of work, the batteries run out quickly, so in such cases, a cutter powered by the mains is used.

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Options for homemade electric foam cutters

Conventionally, such devices can be divided into groups:

• cutter for linear cutting of foam;
• cutter for curly cutting of foam;
• cutter with a working metal plate.

But, despite this separation, all cutters have one common detail.

For their manufacture, you can not do without a step-down transformer.

Such a transformer must be designed for a power of at least 100 watts. Its secondary winding must be rated for a voltage of 15 V and have a winding wire section of at least 1.5 mm.

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Styrofoam Linear Cutter

Image 2. Scheme of a vertical cutter: 1 - cutting nichrome wire, 2 - load, 3 - frame, 4 - working surface.

Such devices are mounted from a working surface (you can use the table surface) with two vertical risers fixed to it, attached to the risers by two insulators, connected to two contacts connected to a step-down transformer and a nichrome thread stretched between the insulators, and also passed through one of the risers freely hanging cargo (image 1).

Such a foam cutter works very simply. Passing through a nichrome thread, electricity heats it, and the suspended load keeps the thread taut, preventing it from sagging, because when heated, it stretches quite a lot. Sometimes, instead of a suspended load, a spring attached to one of the risers is used to tension the thread.

The heated thread easily cuts the body of the moving foam, turning it into flat sheets, the thickness of which depends only on the distance from the table surface to the stretched wire. All you have to do is maintain a steady flow of foam across the table surface.

For vertical cutting of seams, a different cutter design is used, in which the cutting wire is stretched vertically (image 2). A frame is attached to the working surface made of thick plywood or chipboard (indicated by the number 4 in the diagram), preferably welded from a metal profile, but made of wooden bars (3) is also quite suitable.

The frame design provides for the presence of a paw-holder, to which a nichrome wire (1) with a suspended load at the other end (2) is suspended by means of an insulator, passed through a hole drilled in the working surface. Since the nichrome thread will heat up, it is better to make the hole larger and insulate the wooden parts by inserting a metal hollow tube of a hollow diameter into it, through the cavity of which the end of the wire with the load should be brought out.

Such a foam cutter will not only easily cut large pieces of foam into blocks of the desired size, but will also allow you to cut squares, triangles, semicircles and other curly holes in the material if necessary. To do this, it is enough to first draw a cutting line on the surface of the foam with a marker.

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Styrofoam cutter

If you need to cut sheets of large size or thickness, which, due to their size, cannot be placed on the desktop, then in such cases a hand-held electric cutter is used, converted from a hand-held jigsaw or a hacksaw, in which the cutting blade is replaced by nichrome wire.

Image 3. Scheme of a manual thermal cutter: 1 - cutting nichrome wire, 2 - screw with nut and washer, 3 - textolite handle 4-5 mm thick, 4 - electric cord.

Such an electric cutter is not difficult to make with your own hands. At the same time, for the convenience of curly cutting, several working tools can be made. different shapes(image 3). At a jigsaw or a hacksaw, the cutting blade is removed, and an electric wire (4) is connected to the handle (3). Despite the fact that the voltage will not be too high, it is still better to insulate the handle, like other metal elements, at least with ordinary electrical tape. Instead of a cutting blade to a failed electrical cable using screws and nuts with washers, a nichrome wire is attached, bent as needed (4).

As an option, you can also use a wood burning device or a pulse soldering iron for the device of such a cutter. Such a cutter will be even more convenient, since the electric wire was originally provided in the design of these devices. To turn these devices into an electric foam cutter, it is enough to replace the heating working tools in them with a piece of thick nichrome wire, giving it the desired shape.

Such manual cutters are convenient because they can be used not only to cut sheets of foam, but also to cut all kinds of recesses, cavities in them, remove chamfers, in a word, not just cut the foam into pieces, but sculpt real works of art from it.

Styrofoam is a versatile material. It is used in construction (insulation), in the production (repair) of household electrical appliances, interior design, advertising. One of the main characteristics of the material is density. The higher this value, the stronger the material. However, this greatly affects the price.

When using the material as a filler for wall insulation, the loosest structure is usually chosen (due to low cost). However, loose foam is difficult to process - when cutting, it crumbles a lot, making it difficult to clean up debris.

A foam cutting knife should be thin and sharp, but this does not prevent the edge from breaking. Even if you work outdoors, flying small balls litter the environment.

Therefore, professional builders cut the foam with nichrome wire or a hot plate. The material is lightweight despite fire safety.

Important! When choosing a heater, pay attention to the characteristics. It should say "self-extinguishing". Such foam is perfectly cut with the help of temperature, but in case of fire it will not become a source of combustion..

An industrial foam cutting machine can process sheets of any size, cut material both across and along the array.

However, cutting foam at home does not involve such volumes and sizes. At repair work in your home (or garage) a compact thermal knife is quite enough. It can easily cope with both linear cutting and curly adjustment of plates, when laying in areas with complex shapes.


Any tool has a cost, and there is always an opportunity to save money on a purchase.

Do-it-yourself foam cutting tools

For linear cutting, the guillotine is excellent. Only the impact will not be mechanical, otherwise a lot of garbage will be formed. We use a proven technology - cutting foam plastic with a tension heated string.

Required Materials

• Nichrome (tungsten) thread
• Power supply, preferably adjustable
• Any structural materials: timber, metallic profile, pipe, for the manufacture of a tension frame
• Furniture guides for drawers.

On a table, workbench, or other flat surface, we install vertical racks for attaching the guillotine. With the help of furniture guides, we fix the cutter frame so that it moves without distortions. Both sides must move synchronously.


The most critical part of the cutter is the wire mechanism. The first question is where to get the material. Nichrome can be purchased at stores selling radio components. But since we are striving for a shareware design, we will look for an alternative.

1. Old soldering iron. Models made in the USSR, designed for 36-40 volts, can be found in any home workshop. The heater winding is an excellent donor for a nichrome guillotine. True, the length of the wire is not more than a meter.
2. Iron with classic spiral heater. The wire is thicker, suitable for linear cutting. Curly cutting acceptable, with low requirements for accuracy.
3. Spiral heaters from a hair dryer, or a fan heater. The principle is the same, they are not suitable for precise cutting.

note

Tip: When straightening the spiral, do not pull the wire along the spring. Loops may appear and the thread will break. It is better to unwind the turns as from a spool of thread. You can put a spiral on a nail or pencil, and pull the wire across the turns.

The principle of operation of the frame is shown in the diagram.

The wire cutter must be electrically isolated from the frame. Therefore, it can be made of metal. It is important to keep the tension on the wire constant. When heated, nichrome expands, adding up to 3% in length. This causes the string to sag.

The issue of home insulation is very relevant today. Sheathing the facades of houses with foam plastic is one of the most popular types of insulation. And this is very reasonable, because. the process of such insulation is simple and understandable, and all necessary materials always available for sale.

But everyone knows that gluing foam is very convenient on a flat wall. With any method of gluing foam to the wall: dry mix adhesive, foam or adhesive foam, it is always very important that the foam sheet fits snugly against the wall and does not create air gaps.

If the wall is even, then no questions arise. But, unfortunately, the walls of old houses do not differ in ideal evenness. Yes, and different design features structures sometimes create drops on the plane of the wall.

Partially, this drawback can be leveled by laying the foam on a thicker layer of glue. But the maximum allowable thickness of the adhesive layer often cannot cover the magnitude of the differences in the plane of the walls. In addition, too large differences lead to unjustified overspending of glue.

The next way out of the situation remains - cutting the foam in thickness. But doing this with a hacksaw is very inconvenient and time consuming, especially if you need to cut a large amount of foam. In addition, during cutting, a large amount of debris in the form of foam balls is formed. Yes, and the surface is uneven and the accuracy of such cutting is very conditional.

In order to quickly and evenly cut the foam of the desired thickness, you can use a foam cutting machine. This device can be made independently, absolutely with your own hands.

The principle of operation and the device of the machine for cutting foam

The principle of operation of the machine is based on the fact that the foam is easily melted under the influence of temperature. Thus, if you draw a thin heated wire over it, it is easily cut, while forming a perfectly flat, smooth surface.

For the manufacture of the machine, the following components are needed:

• LATR (laboratory autotransformer) or car battery;
• nichrome thread;
• racks for attaching nichrome thread;
• spring (1-2 pcs.);
• tabletop board;
• copper wire.

A nichrome thread (spiral) is used as a cutting object. You can either buy it in a store or extract it from old household appliances in which they were used as filaments (a hair dryer, for example). The thickness of the spiral can be 0.5-1 mm. The most optimal thickness is 0.7 mm. The length depends on the width of the foam to be cut.

An important element of the device for cutting foam is LATR. But if it is not there, then it can be done using an old transformer and a device for charging car batteries.

You can also use a computer power supply that uses wires that give 12 watts (yellow and black) to connect to the spiral.

To operate such a machine, it is enough to have an output voltage of 6-12 watts.

It is necessary to correctly adjust the length and thickness of the filament and to match the voltage. If the thread is too hot, it may break. Well, if the thread is slightly heated, then cutting will be slow.

It can also be used as a power source car battery. They can be used in conditions where there is no electricity on the site.

For different tasks, you can do different designs foam cutters.

Basically, these devices will differ in the length of the spiral. To cut foam into bars, a short spiral length is needed.

You can install two spirals and cut the sheet into several bars in one pass.

Two spirals cut the sheet into three parts in one pass. The stand is stuffed with guides for smooth feeding of the foam.

But, in extreme cases, foam plastic can be cut into bars with a hacksaw. It is much more difficult to cut the foam in thickness, and even with a given size. Therefore, we will consider how to make a machine for cutting polystyrene in width.

Step-by-step instructions for self-manufacturing the machine and cutting foam

Step 1. Preparation of the countertop. As a tabletop for a do-it-yourself foam cutting machine, you can take any piece of chipboard of the right size. The surface on which the foam will move must be smooth. Holes for racks are drilled in the table top. It is convenient to use metal pins with a thread with a diameter of 10-12 mm as racks. The height of the racks should correspond to the thickness of the foam sheets plus a margin in height. The pin is fixed with nuts.

To give the structure stability, bars are attached to the tabletop from below, which will also serve for the safe passage of an electric wire.

Step 2. Connecting the current supply wires. From below, under the tabletop, the wires are connected to metal rod-racks: the wire is wound around the lower end of the pin and pressed with a bolt.

The other end of the wires must be connected to a power source, depending on the method chosen. The best connection will be through a plug, which will be connected to the LATER socket. It is possible to connect via self-clamping terminals, as well as by twisting and soldering. It depends on the selected power supply.

In any case, the connection must be made in accordance with the rules for working with electrical installations and devices, be convenient for work and safe during operation.

Step 3. Fixing the Nichrome Spiral. Nichrome spiral is fixed between two racks. A spring is attached to one end of the spiral (there may be two of them).

The spring is needed in order to pull the nichrome thread during operation. The fact is that when heated, the nichrome thread lengthens and sags. The thread in this state will not give a quality cut. Therefore, the thread is fixed in an initially stressed state, so that the spring is slightly stretched.

To fasten the nichrome thread to the pin, washers with an inner diameter slightly larger than the diameter of the pin are used. A small hole is made in the washer for attaching the spiral itself. A small sharpening is also made on the side of the inner diameter so that the washer can be fixed on the thread of the pin.

A spring with a spiral attached to it is inserted into one washer and put on the first pin. The second washer is put on the second pin and in drilled hole thread a nichrome helix. Next, it is pulled so that the spring is stretched, and fixed.

Step 4: Cutting the Styrofoam To dissolve a sheet of foam into two sheets of a given size, the spiral is set to the desired height. The required distance is measured with a ruler.

The machine is then connected to a power source. The thread heats up and now you can cut the foam, smoothly moving it forward along the countertop.

The cutting speed depends on the temperature of the filament, which in turn depends on the voltage applied and the thickness of the filament itself. Do not try to apply more voltage to achieve high speed, because. this can lead to rapid filament burnout. Here, a balance between tension, thickness and length of the thread must be selected empirically. The thread should not overheat during operation. When heated, it becomes red or scarlet. But it should not turn white - this indicates that the thread is overheating and that it is desirable to reduce the voltage, otherwise the thread will not last long in this mode. Of course, smooth adjustment easily done if LATER is available. But if it is not there, then a laboratory power supply can also be made from a computer power supply, the video below has more information. After you have made this foam cutting machine with your own hands, you need to make sure that the machine is safe.

It must be remembered that all activities must comply with safety regulations for working with electrical appliances. The power supply must be grounded, all connections must be carefully insulated. All work on the assembly of the machine must be carried out with de-energized wires. The machine is connected to the mains only while working with foam. After work, it must be immediately turned off. While working with the machine, touching the metal parts and the nichrome thread itself should be avoided.

Step 4: Cut the Styrofoam at an Angle Sometimes it becomes necessary to cut the foam in such a way that one side is higher and the other lower.

To do this, the spiral is set at a slope with the desired parameters. In this way, foam sheets of various sections can be obtained.

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