Foam Cutter

This project was developed within the Orange Digital Center Morocco , a space dedicated to fostering innovation, creativity, and rapid prototyping. At the FabLab, individuals and teams have access to state-of-the-art tools, including 3D printers, laser cutters, and a variety of electronic and mechanical resources. The center provides a collaborative environment where innovators, entrepreneurs, and students can transform their ideas into tangible products. By focusing on sustainable and impactful solutions .

Envision foam cutter prototype using a heated copper wire, designed to provide precise and smooth cutting of foam materials. This innovative device works by leveraging the resistance of the copper wire, which heats up quickly to melt the foam cleanly and effortlessly. Thanks to its ability to adapt to various shapes and thicknesses of foam, it enables extremely detailed and customized cuts, ideal for applications ranging from modeling to prototype creation. This foam cutter with copper wire transforms the manufacturing process, offering both efficiency, precision, and ease of use. Whether you're a craftsman, designer, or engineer, this prototype will allow you to carry out your most complex projects with ease and perfection.

the components used:

1. Generator: generates voltage and current aquired to power the cutter.
2. Nut screw: is used to securely fasten parts together.
3. Copper wire: we use 20cm, conduct electricity due to its high conductivity.
4. Alligator clips: in this we use two, are an extremely useful tool for making temporary electrical connections and facilitating tests in electrical and electronic circuits.

We create a sturdy and efficient foam cutter frame using a CO2 laser cutter and 3mm plywood. With just 3mm plywood and basic tools, you’ll be able to build a functional foam cutter frame that’s both lightweight and durable.

Materials Needed:

1. 3mm plywood
2. CO2 laser cutter
3. Alligator clips.
4. Basic tools for finishing (glue, sandpaper, etc.)

You need to glue the alligator clip to the bottom frame to secure the lower end of the copper wire.

The pieces above are designed to suspend the copper wire in place. The alligator clip is attached to the generator, allowing it to heat the wire. This setup ensures precise and efficient foam cutting.

The generator settings should be adjusted between 2.30 to 3.0 Amperes and a voltage range of 5 to 7 volts. This ensures the copper wire heats up properly without burning, while also protecting the alligator clips.

Whether you're a beginner or an experienced maker, this foam cutter delivers accuracy and simplicity. Transform your ideas into reality with technology designed in a hub of creativity and innovation.