Cutting foam at home - a knife or a homemade machine? Homemade foam cutter - buy or do it yourself? Styrofoam cutter.

Heat and sound insulating building materials on the market are presented in a wide range, these are foamed polyethylene, mineral and basalt wool and many others. But the most common for insulation and soundproofing is extruded polystyrene foam and polystyrene, due to its high physical and chemical properties, ease of installation, low weight and low cost. Polyfoam has a low coefficient of thermal conductivity, a high coefficient of sound absorption, and is resistant to water, weak acids, and alkalis. The foam is resistant to the effects of ambient temperature, from the lowest possible to 90˚C. Even after decades, the foam does not change its physical and chemical properties. The foam also has sufficient mechanical strength.

Styrofoam also has very important properties, these are fire resistance (when exposed to fire, the foam does not smolder like wood), environmental friendliness (since the foam is made of styrene, even food products can be stored in containers from it). Fungi and foci of bacteria do not appear on the foam. An almost ideal material for insulation and soundproofing in the construction and renovation of houses, apartments, garages, and even packaging for food storage.

In shops building materials Styrofoam is sold in the form of plates of different thicknesses and sizes. When repairing, foam sheets of different thicknesses are often needed. With an electric foam cutter, you can always cut sheets of the desired thickness from a thick plate. The machine also allows shaped foam packaging from household appliances turn into plates, as in the photo above, and successfully cut thick sheets of foam rubber for furniture repair.

How easily foam is cut on a homemade machine, the video clip clearly demonstrates.

If you want to make a cutter for foam plastic and foam rubber, many are stopped by the difficulty of organizing the supply of supply voltage to heat the nichrome string to the desired temperature. This obstacle can be overcome if you understand the physics of the issue.

Machine design

The basis of the device for cutting foam was a sheet of chipboard (chipboard). The size of the plate must be taken based on the width of the foam plates that are planned to be cut. I used a 40x60 cm furniture door. With this size of the base, it will be possible to cut foam plates up to 50 cm wide. The base can be made from a sheet of plywood, a wide board, and the cutting string can be fixed directly on the desktop or workbench.

Stretching a nichrome string between two nails is the limit of laziness home master, so I implemented the simplest design that provides reliable fixation and smooth adjustment of the height of the string during cutting above the surface of the base of the machine.

The ends of the nichrome wire are attached to the springs, dressed on M4 screws. The screws themselves are screwed into metal racks pressed into the base of the machine. With a base thickness of 18 mm, I picked up a metal stand with a length of 28 mm, so that when fully screwed in, the screw does not extend beyond the bottom side of the base, and when the maximum unscrewed state provides a foam cutting thickness of 50 mm. If you need to cut sheets of foam or foam rubber of greater thickness, then it will be enough to replace the screws with longer ones.

To press the rack into the base, first a hole is drilled in it, with a diameter of 0.5 mm less than the outer diameter of the rack. In order for the racks to be easily hammered into the base, the sharp edges from the ends were removed on an emery column.

Before screwing the screw into the rack, a groove was machined at its head so that the nichrome wire could not move arbitrarily during adjustment, but occupied the required position.

To make a groove in a screw, first its thread must be protected from deformation by putting on a plastic tube or wrapping it with thick paper. Then clamp the drill in the chuck, turn on the drill and attach a narrow file. In a minute, the groove will be ready.

To prevent sagging of the nichrome wire due to elongation when heated, it is fixed to the screws through springs.

A suitable spring from a computer monitor, used to tension the ground wires on the kinescope, turned out to be suitable. The spring was longer than required, I had to make two of it, for each side of the wire attachment.

After preparing all the fasteners, you can fasten nichrome wire. Since the current consumed during operation is significant, about 10 A, for reliable contact of the current-carrying wire with nichrome wire, I used the method of fastening by twisting with compression. Thickness copper wire at a current of 10 A, it is necessary to take a cross section of at least 1.45 mm 2. You can select the wire section for connecting nichrome wire from the table. I had a wire with a cross section of about 1 mm 2 at my disposal. Therefore, each of the wires had to be made of two with a cross section of 1 mm 2 connected in parallel.

If the electrical parameters of the nichrome wire are not known, then you must first try to connect a low-power electrical appliance, for example, a 200 W electric light bulb (a current of about 1 A will flow), then a 1 kW (4.5 A) heater, and so increase the power of the connected devices until the nichrome the torch wire does not reach the correct temperature. Electrical appliances can also be connected in parallel.

The disadvantages of the last connection scheme of the nichrome spiral include the need to determine the phase for correct connection and low efficiency (coefficient useful action), kilowatts of electricity will be spent uselessly.

In construction and finishing work rightfully occupies a worthy place foam. Its heat-insulating and noise-absorbing characteristics allow it to be used in the decoration of facades, country houses, and industrial enterprises. The construction of the material consists of foam particles that fill the gas cavity during molding. The cost of the material is not high, it can be used in any field of activity, large letters on advertising, information boards, etc.

Basic Methods for Cutting Styrofoam

Most the best option The thermal insulation of the building is polystyrene foam. Usually, a non-dense structure is chosen for these purposes, due to the low cost. This causes inconvenience when cutting, the structure of the cells crumbles, and with a little effort, you can break the structure with your hands. The foam cutting tool has various modifications, ready-made options are sold, you can also make a design with your own hands.

It is important to understand that the structure of the foam is categorically related to the impact of certain liquids. Acetone or gasoline destroys the structure of the foam, the product will have to be made again. Temperature operation modes are no more than 50 °.

Cutting foam at home is performed by many improvised tools. For example, when working with small workpieces, the most in a simple way is to use a utility knife. The process is inaccurate, because the blade dulls quickly, for better processing the knife can be heated.

Each of the devices has advantages and disadvantages; before cutting with your own hands, it is important to note the characteristics of the foam, to choose a tool for cutting the foam to size.

In hardware stores you can buy a special tool - a knife with a heated blade. Work with this device is carried out on its own, in order to avoid slipping and injury. Main disadvantages cutting knife that they can cut material of a certain thickness, for smooth work you need to correctly mark the product, spend time on it.
A type of heated knife can be a soldering iron with a special nozzle. More different high temperature heating, during work it is necessary to be careful, a molten drop does not deliver joyful sensations when it comes into contact with the skin.
A shoe knife for cutting foam is used with a long blade up to 40 cm. The tip of the knife remains blunt, and the wide blade must be perfectly sharpened. Adjustment and sharpening is carried out every 2 meters of the cut product. The process will be accompanied by a squeal, you can eliminate unpleasant sounds by using headphones.
Thicker pieces can be cut with a fine-toothed wood saw. The lower the level of the teeth, the better quality output part, however, scuffs and bevels will still be present. The method does not require the application of special products, it is often used for long straight cuts of foam.
The most popular way is to cut the foam with a string. The performance of this method is equal to industrial equipment, it is enough to build a small structure. The string is used when working with foam plastic of various grain sizes and densities.

Some cases, in the absence of any of the above cutting tools, require the intervention of electrical engineering. The grinder is used with a disc of minimum thickness. The work implies the presence of increased noise, debris from foam particles throughout the territory.

The processes of work on the insulation of one dwelling can be performed with a manual type tool. The wire for influencing the foam is used on a special stand, previously prepared. The design consists of nichrome wire, easily made by hand. The connection diagram consists of two fasteners, a load for tension and power to the network. In cases where production volumes are increased, special foam processing machines are used.

You can buy them in specialized stores, as well as make your own.

Machine classification

The design features of the units do not differ from each other. In each of them, cutting occurs due to a heated wire fixed in a certain position. Some of the modifications have up to six adjustable strings, this allows for more massive work. Foam cutting machines can be with turntable, permanently fixed cutting element.

Devices are divided into several categories:

software-controlled equipment that allows you to cut figures of increased complexity;
portable cutting elements;
transverse or horizontal types of cutting.

The most complex machines in design allow you to work on several planes of the product at once. The performance of foam cutting machines is designed for industrial purposes; in one go, some models can process over 10 meters.

Do-it-yourself foam cutting tools

Home insulation materials are always available for sale. It is best to glue the foam on flat wall, but if protrusions are found, the shape of the foam will have to be adjusted. Styrofoam cutting is carried out both by purchased equipment and by self-made.

To build a structure, it is important to select the parameters and drawings. The type of work also depends on the design and its dimensions. Cutting foam at home is carried out from improvised means, the main thing is to choose the right materials. It is important to comply with safety requirements, when cutting, slippage of the product, damage to the limbs is possible.

In the process of heating the foam, fumes are released, if inhaled, they can damage the mucous system of the worker.

Homemade thermal cutting knife

It is possible to correct the shape of insulation products, cut out small products and blanks with a thermal knife. To cut foam you will need:

A krone-type battery with an output voltage of 9 volts, or a set of finger products.
The nichrome fishing line is stretched between the plates, the length is not more than 10 cm.
Several wires connect the ends of the wires to the battery.

The simplest cutter can be assembled from improvised means, it will help to chamfer corners, perform the necessary fitting of polypropylene parts. It is necessary to install a power button that will activate the device, this is done for convenient, safe operation.

DIY nichrome cutter

Do-it-yourself production implies the presence of certain means. In order to qualitatively assemble a tool for cutting foam, you will need:

nichrome wire, it can be purchased at radio parts stores of the required size;
a 12 volt step-down transformer, it is a computer power supply or a car battery charger;
long needle;
rheostat, which makes it possible to regulate the strength of the current;
electrical wires suitable for connection are long.

The device can be mobile or fixed on a table. The frame is made of wood, the wire is set to a height of 10-15 cm, on the adjusting screws. The screws that secure the nichrome wire must be of the right length to adjust the height to the desired level. A weight is suspended from one side of the screw to tension the wire for a straight cut level.

The impact of current leads to splitting of the wire, the foam is easily exposed to temperature effects. The edges are sealed, this prevents the decay of the structure of the material. The cutting of the foam begins after the appearance of a red tint on the wire, it is not necessary to bring the incandescence to a high level, in these cases the width of the cut will be too large.

When performing the procedure, you should use personal protective equipment, a mask, gloves. The melting process releases toxic fumes.

Cutting is done indoors with good ventilation or outdoors.

Design features and principle of operation

The string expands when heated, adds up to 3% in length, cutting with a sagging cutter will not be of high quality, so a special mechanism is added to the design. With actions with a low frequency, it is possible to use a spring, it will gradually stretch the wire to the desired state. Mass use means fast stretching, so it's best to use a suspended weight to one side of the string.

The foam cutter is powered by power sources with an output voltage of 12 to 36 volts. Most good option a laboratory transformer can be distinguished. The device is able to withstand high loads, to smoothly adjust the output voltage.

Specialized machines and their prices

The manufactured machines are delivered for mass production. There are modifications with six cutting elements, which allows you to quickly cut a large amount of foam in one run. Laser machines perform work for architectural purposes, are able to cut various shapes, materials in thickness.

Machines have excellent characteristics, can have the functions of simultaneous processing of many elements, and have high productivity. The price of devices is high, you need to know exactly what the cutter is used for.

Frp 01

A simple design allows you to modify the device for various shapes and sizes of foam blanks. Styrofoam cutting tools various types allow you to take a number of actions. Implemented the ability to trim linear parts, curly elements, insulation boards and signboards.

The cutting is done by the machine by connecting to the CNC. The cutting program is supplied with various settings. The price of such a device starts from 110 thousand rubles, it is important to check the functionality and reliability of the design before buying.

SRP "Kontur"

There are modifications of machines for the production of elements of various shapes. Styrofoam cutting machine is manually operated, has simple design rich functionality. The power consumption is not high, the components are collapsible, which allows you not to worry about transportation.

The cost of equipment starts from 40 thousand rubles. The main difference between market models and hand-made ones is the tests carried out for the safety and reliability of parts.

Self-made cutting machine

A complete machine can be made at home. For the manufacture of the machine, a tabletop and a frame of the desired width, as well as other details, are selected. A do-it-yourself foam cutting machine is made from improvised means, by analogy with the smallest nichrome modification. There are several modifications and structures of machines, implemented in accordance with the conditions of the parts.

Manual cutting of styrofoam

Of all the above methods, manual cutting of foam is not so expensive, an abundance of methods allows you to influence foam products in accordance with the tasks.

The simplest and least expensive way is cutting with large sharpened knives. The tip of the knife is left blunt, oil must be distributed across the width of the knife for lubrication, the speed of this method is not high, cutting of small volumes is used.
A hot rune allows you to quickly perform work, but is harmful to health.
Cold wire cutting is similar to the action of a saw, it is only necessary to make a productive structure.
Cutting with a hacksaw blade.

Professional methods involve the use of a ready-made tool. High-quality and fast cutting is carried out by using suitable devices.

Homemade machine on the table

If there is a large table and workplace, this will significantly save time and effort, because when using manual methods, the material crumbles and deteriorates. A home-made machine and its foam cutting design is performed by using a nichrome string.

A suitable power source is used, which produces from 12 to 36 volts. It is possible to use the voltage of a regular network, but only there is a wire coated with nickel, this method causes an electric shock, which is significantly felt by a person.

The machine for figured cutting of polyfoam

Complex geometric shapes can be processed with a special machine. The device allows you to make figured cutting of foam plastic with your own hands. The design is carried out according to the same principles, only the nichrome wire is stretched vertically.

The fastening mechanism fits on one side, which makes it possible to move the product on the tabletop.

Styrofoam is quite practical and lightweight thermal insulation material. It is often used to create various crafts. However, in the process of working with it, one has to face one trouble - the material is difficult to cut. Foam plastic is produced in the form of large slabs, and in order to divide the panel into fragments, you will need to cut it.

Using a saw or knife for this purpose will not work. This is due to the fact that with any mechanical action, the structure of the material is destroyed. To avoid this, you will need to design a foam cutter with your own hands.

The simplest device for cutting foam

The simplest foam cutter is easy to do with your own hands. For this purpose, you will need to use the thinnest guitar string. In addition, you should prepare 5 large batteries for a conventional electric flashlight. They must be connected in series. A string is connected to the ends of the device, thereby closing the electric arc. The current will pass through the string, heating it.

When using such a device, the foam sheet will separate into two parts immediately after touching the string. In this case, the material will melt along the cut edges. The cut with such processing is obtained as even as possible. The string for cutting foam must be heated to a temperature of at least 120 degrees. However, it should not exceed 150 degrees.

Checking how hot the string is is quite simple. During cutting, stuck pieces remain on the edges of the material. If they are too long, the string is not heated enough. In the absence of such pieces, it can be judged that the string is overheated.

When using such an elementary device, about 3 foam panels can be processed. However, it is not suitable for large volumes of work. Batteries run out pretty quickly. To extend the time of the cutter, you will need to build a mains-operated device. A few simple tips will help you understand how to make a foam cutter.

Homemade electric foam cutters

If we divide such devices into groups, they should be classified as follows:

device for linear cutting;
thermal cutter, with which curly cutting is performed;
device with a metal plate.

However, despite this classification, each device has one common element in its design. To create foam cutters, you will need to find a step-down transformer. It is necessary that this element withstand 100 watts.

Linear cutter

To create such devices, you should prepare a workspace. Usually a table is chosen for such purposes. Two vertical risers are attached to it. Each of them must have an insulator. A nichrome thread must be pulled between the insulators. A freely hanging load is hung on it. The nichrome thread is connected to the contacts connected to the step-down transformer.

The principle of operation is quite simple. The nichrome thread heats up when connected, which makes it easy to cut the foam. Due to the suspended weight, the thread remains in a taut position. The load is necessary because the thread begins to sag when heated.

Moving foam is cut with a nichrome thread quickly and evenly. How thick the processed sheets will be depends on the height of the thread above the working surface of the table. The main thing is that the foam is fed at the same speed throughout the entire cutting period.

To cut sheets vertically, you will need to use a cutter of a different design. In it, the cutting wire is stretched in a vertical position. In this case, the work surface is made of chipboard. A frame must be attached to it. It is better if this element is made of a metal profile. However, wooden blocks work well.

The frame is equipped with a paw-holder, on which a nichrome wire is suspended. A load is attached to its end. The wire is passed through a hole made in the working surface. So that it does not touch the tree, the hole is protected from the inside with a metal hollow tube.

When using thermal cutters, the foam is not only easily cut into certain blocks. From large plates, various geometric shapes can be cut, such as a square, a semicircle, a triangle. Before work, it is enough to draw a marker over the surface of the plate, marking the cut line.

Curly cutter

When working with foam sheets big size it will be difficult to use a stationary cutter. Such panels are difficult to fit on the desktop. In these cases, a manual foam cutter is used. Such a tool is often made from a jigsaw. The cutting blade in these tools should be replaced with nichrome wire.

Such an electric cutter is quite simple to build with your own hands. To make cutting curly elements more convenient, you can make several devices with different shapes. First, the cutting blade should be removed from the jigsaw, and the wire should be connected to the handle. The voltage will be low, but the handle and other metal parts should be insulated. A nichrome wire is connected to the cable. For this, nuts are used. The wire is bent in a certain way.

as a cutter for curly cutting foam can use a soldering iron. It needs to be modified a bit. The device already has in its design electrical wire. To create a foam cutter from a soldering iron, you will need to replace the element that heats up with nichrome wire.

This device is very easy to use. Thanks to this product, it is possible not only to cut material slabs into smaller sheets, but also to make recesses in them.

Metal plate cutter

There is another way to convert a soldering iron into a foam cutter. To modify the tool, you just need to replace the sting with a copper plate. Steel is also suitable, but it heats up longer and is more difficult to sharpen. However, if properly sharpened with a steel plate, it will be possible to cut any synthetics, including foam.

One side of the plate must be carefully sharpened. Sharpening can be done on both sides. It is necessary that the sharpening angle is not too large. The cutting of the material is carried out not only by the blade, but also by the plate blade. Such a cutter has one drawback - you will have to empirically find the optimal temperature for heating the knife.

conclusions

Building a foam cutter with your own hands is quite simple. The methods listed above will help you understand the device and the principle of operation of the foam cutter. Such devices are practical and easy to assemble. Each method has its own advantages, so home craftsmen can choose the most suitable one for themselves, depending on the materials available.

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 shape.

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: beam, metal 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 frame of the cutter 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.

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.
Iron with classic spiral heater. The wire is thicker, suitable for linear cutting. Curly cutting is acceptable, with low requirements for accuracy.
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.

Curly cutter

When working with large foam sheets, it will be difficult to use a stationary cutter. Such panels are difficult to fit on the desktop. In these cases, a manual foam cutter is used. Such a tool is often made from a jigsaw. The cutting blade in these tools should be replaced with nichrome wire.

A soldering iron can be used as a cutter for curly cutting foam. It needs to be modified a bit. The device already has an electrical wire in its design. To create a foam cutter from a soldering iron, you will need to replace the element that heats up with nichrome wire.

This device is very easy to use. Thanks to this product, it is possible not only to cut material slabs into smaller sheets, but also to make recesses in them.

Metal plate cutter

conclusions

Great care must be taken when working with these power tools. This is due to the risk of electric shock. Some homemade cutters are also used to cut Styrofoam.