Polystyrene foam is a universal material with uniquely high sound-absorbing and heat-insulating capabilities. For this reason, it is often used to insulate residential buildings. If desired, foam plastic can be cut into blanks of any size at home. Let's see how it's done.

How to cut polystyrene foam at home?

Thermal insulation of private houses and apartments can now be done with a variety of materials. At the same time, foam plastic has remained one of the most popular insulation materials over the past decades, due to its affordable cost, low weight, and resistance to alkalis, weak acid solutions, and water. The material we are interested in does not change its properties for a long time. It is not afraid of high (up to 90 °C) temperatures, is characterized by good mechanical strength, high noise absorption and low thermal conductivity. Pockets of bacteria and fungus never appear on it.

Polystyrene foam is famous for its environmental safety (it is made from styrene, which is recommended for the production of food storage containers) and fire resistance (it does not smolder when exposed to fire). Construction stores sell it in sheets. The thickness of the latter varies between 10–100 mm. Many manufacturers also produce polystyrene foam to order. The thickness of such products can reach 500 mm. When installing, foam plastic has to be cut into blanks of certain sizes. This is not as easy to do as many home craftsmen think when faced with a similar task for the first time. Cutting foam plastic has many nuances and tricks. If you deal with them, the process of cutting the material will take a minimum of time.

At home, cutting the described insulation is carried out using:

• various types of knives;
• soldering iron with a special nozzle;
• strings;
• hacksaws for wood;
• Bulgarians;
• homemade machine.

Next, we will describe in detail the tools and devices used for cutting foam plastic, and consider the advantages and disadvantages of their use. And then any self-taught master will be able to decide for himself which cutting method suits him best.

We use hand tools - not ideal, but an acceptable option

If the foam sheets have a minimum thickness (10 mm), it is quite possible to cut them with a simple stationery knife. There is one peculiarity here. When cutting a large number of workpieces, the knife will become dull. Because of this, the foam will begin to crumble around the edges. It will be impossible to achieve an even cut in such situations. It is not difficult to avoid such a problem. You just need to warm up the tool a little before cutting the next sheet.

It is better to work with products with a thickness of 20–40 mm using a shoe knife. But only on condition that its edge is dull and the blade itself is very well sharpened. Important! A shoe knife should be sharpened very often. We made 3-4 cuts. They took the sharpener. The sharpness of the blade was restored. We continued cutting. Significantly fewer problems arise if you use a special knife for working with foam plastic. At the end of such a tool there is a rubber nozzle.

The special knife cuts workpieces quickly and accurately. But working with him is dangerous. There is a possibility that the tool will slip off the workpiece and injure a person. Reducing possible risks is not difficult. It is enough to secure the foam sheet in a vice. And only after that cut it. Note! The knife should always be moved away from you. This also reduces the risk of injury.

Another special tool – a thermal knife – also provides high-quality cutting. It is a soldering iron with a nozzle. This device heats up during use, which allows you to cut material without any physical effort. When working with a thermal knife, you must be extremely careful. When heated strongly, it will begin to melt the foam. Drops of the latter can get on the master's hand or on his clothes.

Thick sheets (80–100 mm) can be cut with a fine-toothed hacksaw designed for cutting wood.

Foam plastic can be easily processed with such a tool. But this method is only suitable for cases when we need to get a straight, long cut. We will not do figured cutting of products using a saw. Large sheets can also be cut with a grinder. You just need to put a metal disc of minimal thickness on it. The disadvantages of the technique are the loud noise from the grinder and the squealing from the material being cut, as well as a large amount of debris. Pieces of polystyrene foam will fly all over the room. Collecting them will subsequently take a lot of time.

Homemade machine - cuts sheets of any size and thickness!

The most effective way to cut foam plastic involves using nichrome string (wire). It provides high productivity of the operation and almost complete safety for the master. In order to use the string, we need to build a simple stationary cutting machine. To make it we will need:

• nichrome thread (wire);
• old table;
• rheostat;
• drill;
• spring;
• electric wires;
• M24 screws;
• transformer;
• metal rod.

Nichrome wire is easy to obtain. It is used in a variety of heating household appliances (electric kettles, water heaters, irons, stoves, hair dryers, air heaters, and so on). We simply find a broken device and take out the thread we need from it. You cannot use regular steel wire. Nichrome is a combination of nickel and chromium, which has great mechanical strength and high electrical resistivity. It is optimal to use wire with a cross section of 0.6–0.8 mm. It can easily cope with cutting all standard thickness foam sheets.

The diagram for making a machine with your own hands will be as follows. We make the tabletop from wide boards, plywood sheets or chipboards. If the household has an old unnecessary table, we use it to create the base of a homemade machine. We drill two holes at a distance of 0.2 m from each edge of the tabletop (we place them along the center line of the structure). We insert screws into them from the reverse side. Instead of these hardware, you can install two racks made of a metal rod. We fix the screws with nuts.

Next, we fix the nichrome string on one of the racks (it should be at a height of 10 cm from the surface of the tabletop). We mount a spring on the second support. We fix it securely. Attach the second end of the wire to the spring. This complicated string installation scheme is due to the fact that the nichrome thread will expand when heated. This will cause it to sag, which will complicate the process of cutting the foam. If the thread is attached to a spring, the latter will compensate for the expansion. This precaution will eliminate the possibility of the cutting wire sagging.

The next step is to connect the electrical wiring to the racks. Nuance! We connect the wires from the bottom of the tabletop. Then, when using the machine, they will interfere with the movement of the foam sheets being cut. Then we connect the wires to the transformer (LATR). The homemade machine will be connected to the network through it. We take any transformer. The main thing is that it can withstand a load current within 8–10 A. We place the LATR under the tabletop. We turn on our machine. We begin to cut out the foam using nichrome. We apply a sheet of material to the string and lightly press on it. We get a perfectly even cut.

Important addition. Experienced craftsmen advise equipping a homemade machine (its transformer) with a rheostat. This elementary device will make it possible to select the optimal amount of current supplied to the cutting device, due to which we will be able to regulate the temperature of the nichrome string. The presence of a rheostat simplifies the cutting process and also extends the operating time of the transformer.

Greetings. In this article I’ll tell you how to make a machine for cutting foam plastic yourself, using available materials. I am sure that the topic will be of interest to many, because polystyrene foam is a popular building material, which during installation must be cut to the required size.

A regular hacksaw is not suitable for even cutting of this material, since the set teeth leave ragged edges of the cut. How to cut polystyrene foam at home? Special machines equipped with an accumulating thread ensure optimal cutting quality. And it is about this equipment that you will learn further.

Basic Information About Foam Cutting Machines

Construction polystyrene foam is a polymer cellular material that, when heated to a temperature of +270 ° C, does not burn, but melts. All machines for figured cutting of polystyrene foam are built taking into account the tendency of the material to melt when heated.

The working tool in the design of such equipment is a filament - a metal refractory nichrome wire for cutting. A current with a small voltage is supplied to the wire, which is sufficient to heat the metal to a red glow. The workpiece is fed to the working tool and cut along a straight or curved path.

The advantage of this cutting principle is the immobility (staticity) of the cutting element, due to which high precision and accuracy of the cut can be achieved. High-precision industrial equipment, which produces complex foam products, is equipped with CNC.

On sale, cutters for polystyrene foam are presented in devices with different dimensions, different power consumption and productivity. If you think that the price of purchased equipment is high, I suggest that you familiarize yourself with the instructions for assembling an inexpensive portable knife and stationary cutter yourself.

Making a portable compact knife

A foam cutting knife is a portable tool that can be used directly on a construction site, for example, when insulating walls with polystyrene foam boards.

To assemble a portable cutter at home, you will need the following materials:

• Nichrome thread with a cross-sectional diameter of 0.4-0.5 mm;
• Wooden strip or other dielectric materials for making a frame;
• 2 bolts with a nut and washer (the size is selected according to the dimensions of the frame);
• Twin cable;
• PC power supply with 12 volt output;
• Electrical tape or fastening ties.

The instructions for making a portable cutter are as follows:

• A frame is assembled from slats or other available materials in the shape of a bow, as in the photo, or in the shape of the letter “P”;
• One through hole is drilled at the ends of the frame;
• Bolts are screwed into the holes, as shown in the photo;
• On the inside of the frame, the ends of nichrome wire are wound to the bolts;
• On the outside of the frame, one end of a two-core cable is attached to the bolts;

• The cable is secured to the frame with electrical tape or plastic ties;
• The free end of the cable is connected to the corresponding terminals of the power supply.

The finished tool is suitable for cutting polystyrene foam, polyurethane insulation, plastic bottles and other polymer materials with a small thickness and low density.

The cutting ability of a knife directly depends on the size of the frame. The narrower the frame, the higher the resistance on a piece of wire, and the more it heats up. Conversely, the wider the frame and the longer the wire, the lower the resistance and the weaker the heating. To work with foam plastic, I recommend using a wire 40-45 cm long (frame width).

Considering the high heating temperature of the string, I recommend using thick protective gloves when working with the instrument, which will prevent the risk of burns.

Making a stationary cutter

You can buy a machine for cutting polystyrene ready-made, or you can assemble it yourself with minimal expense.

To assemble a stationary machine we will need:

• Chipboard or tabletop 50x50 cm for making a frame;
• Rail or block for support legs;
• Self-tapping screws for assembling wooden parts;
• Threaded rod (diameter 10 mm length 80 cm);
• Nuts and washers;
• Nichrome wire (section diameter 0.4-0.5 mm);
• The connecting wire is two-core;
• Switch.

The assembly instructions are as follows:

• From a sheet of chipboard or a material of similar quality, a square frame with a side of 50 cm is cut;

• At the bottom of the frame, slats are screwed on both sides, which will serve as legs;

• We find the center of the bed and draw a longitudinal center line;

• We retreat 3 cm from the edge of the frame and drill a through hole with a diameter of 8 mm;
• We also drill a through hole in the center of the frame, but this time with a diameter of 3 mm;
• We measure 70 cm on the stiletto heel and cut off the excess;
• We measure 45 cm on the prepared hairpin and bend it along this mark;

In order for the pin to bend without breaking, it must be heated with a blowtorch or acetylene torch.

• From the end of the long side, screw a wing nut onto the stud and put on a washer;
• We insert this end of the pin into the hole drilled in the frame;
• We grab the end of the stud with a nut and tighten it on the other side with a wing so that the structure is stable;

• We turn the frame upside down and next to the hole, as shown in the photo, we attach a bronze adapter with terminals;

• We attach one end of the two-core wire to the adapter;
• A terminal with a ring, the diameter of which is 8-10 mm, is attached to the second end of the wire;

• We securely fasten the wire to the frame;

• We connect the switch to the gap in the connected wire;
• From the bottom of the frame we pass nichrome wire through the drilled hole;
• We fasten the end of the wire in a bronze adapter;

• We fasten the second end of the wire between two washers and nuts, as shown in the photo;
• Tighten the nuts and at the same time tension the wire;
• We connect the device to a power supply with 1-2 volts at the output, as was done in the previous instructions;

• At this point, the assembly of the cutter is completed and you can begin a test run of the tool.

The advantage of a stationary tool over a portable analogue is ease of use. That is, the part can be placed on a static bed and moved towards the hot string at the required angle.

By the way, we remember that the string is heated to a high temperature, and therefore, in order not to get burned, we work carefully.

Conclusion

Now you can try to assemble a foam cutting machine yourself. If you have questions during production, ask them in the comments to the instructions.

By the way, if you know other ways to make tools for cutting polystyrene foam, write about it. I'm sure everyone will be interested in hearing about your experience. And, as always, I recommend watching the video in this article.

The foam cutting machine allows you to make products of various shapes from polymers. The latest developments are controlled by the operator via a computer, and homemade machines are easy to manufacture, but no less effective.

Types of machines and operating principles

In specialized stores you can find a machine for cutting foam plastic of the following type:

• mobile (similar to a knife);
• for horizontal and cross cutting;
• with numerical program control.

The operation of many machine models is based on a single mechanism. The cutting surface heats up and separates the polystyrene foam according to the drawing, just like a hot knife cuts butter. Often a fishing line is used as a cutting surface. The simplest homemade machines operate with a single string. High-precision CNC models cut with six lines simultaneously.

The cut is clean and there is no need to further process it.

Design of machines for shaped cutting of foam plastic

You can cut a sheet of foam plastic with your own hands on a machine in two ways: vertically and horizontally. For vertical cutting, the line is placed perpendicular to the working surface. To make an even cut, drawings and templates are used. The optimal material for cutting is nichrome thread.

When choosing a machine, the length of the workpieces is important. For example, there are models for cutting polystyrene foam with lines longer than 2 m. In one cycle, such a machine produces 12 linear meters of products according to the drawings.

For cutting more complex elements from polystyrene foam, for example, toys, design objects, special models of machines for figure cutting have been developed. Expanded polystyrene is processed in several projections. From simple material you can make a model of an airplane, a figurine of a person or animal, or complex patterns.

Capabilities of polystyrene foam cutting machines

Shape cutting machines can be used in a wide variety of industries, from construction to advertising business. No waste is generated during cutting, and the melted surfaces receive additional strength. The thickness of the material is limited only by the length of the thread.

Using the drawings you can do it yourself with great precision:

• figures according to any drawings made of polystyrene foam;
• molds for the foundry industry;
• forms for pouring concrete solutions;
• stands for exhibitions and presentations;
• logos, letters for external advertising;
• cornices, rosettes, arches and moldings for interior decoration;
• packaging parts;
• foam molding.

The following materials can be cut into shapes: foam rubber, polystyrene foam, any polymers that can be processed with a heated fishing line.

The thermal method of creating shaped parts from foam plastic has only one drawback: during heating, harmful substances are released from the polymer. Therefore, the workplace must be equipped with a good hood!

Homemade machine for figure processing

You don’t need any drawings to make the machine yourself, it’s such a simple device. This machine can be used to produce small parts for fishing or household use.

1. We select a suitable table covered with an electrical and thermal insulator (for example, polyamide film).
2. At the centers of the long sides of the table we attach one glass or ceramic insulator. Then a filament will be stretched between the insulators.
3. We select a suitable fishing line. You can use nichrome thread from an old iron, soldering iron or electric stove. The spiral should be straightened into a straight thread. The thickness of the fishing line should not exceed 0.5 mm.
4. To prevent the thread from burning out, we connect it to the network through a step-down transformer or rheostat.
5. A fishing line is connected to the coil on the insulator with your own hands, and an electrical installation cable is connected to it, which will go further into the network. Maximum contact between line and cable should be ensured.
6. Under the table, the fishing line is pulled to the second insulator and passed through it. The end of the fishing line hangs freely from the insulator, and a weight is screwed to it. The weight of the weight regulates the tension of the heated fishing line during operation; it must be selected by trial. Thus, we make a sliding fastening, which ensures better cutting cleanliness.
7. Near the second insulating coil, another electrical cable is attached to the fishing line, directed to the rheostat (slider terminal).

The homemade machine starts only after setting the rheostat slider to the maximum resistance value. Otherwise the thread will burn out instantly!

The performance of a do-it-yourself machine will depend on the heating temperature of the fishing line, that is, its thickness and current voltage. It is not recommended to apply high voltage to speed up the process. Because the thread will burn out faster. It is necessary to monitor the condition of the thread; it should heat up to a bright red color, but not white. White color indicates overheating. That is, the current voltage must be reduced and made acceptable for operation.

Despite the huge number of insulating materials (which, by the way, is constantly growing), as well as the growing popularity of mineral wool, polystyrene foam still occupies a leading position and has no plans to give it up. If you plan to insulate the floor in an apartment or basement, then cutting polystyrene foam can be done quite well with the help of available tools, but if we are talking about significant volumes or unusual tasks, then a special device is needed - a machine for cutting polystyrene foam.

Foam cutting machine

Classification of machines

On the modern market, such machines are presented in a fairly wide variety. In this case, you can purchase a special unit for laser cutting or, as an option, try to make something similar yourself.

By the way, all machines are conditionally divided into the following categories:

• portable units (vaguely reminiscent of a knife);
• CNC units;
• for slicing crosswise or horizontally.

Design features and principle of operation

Even though the machines exist in a wide variety of modifications, the principle of operation of all of them is generally the same. The edge, heated to a high temperature, passes through the foam layer in the required direction, like a hot knife through butter. In most cases, fishing line is used as such an edge. In the simplest models there is only one such heating thread, while in more advanced devices there can be several of them at once (up to six strings).

Note! If you plan to cut molded elements, then special attention should be paid to the length of products that can be processed.

As an example: the SRP machine, which is also used for cutting the described material, is equipped with strings over 2 meters long, and in one pass it can cut about 12 linear meters. meters of material.

Specialized machines and their prices

Often, polystyrene foam is used not for insulation or soundproofing of buildings, but for the production of advertisements or in interior design. This is possible thanks to the use of special machines designed for figured cutting. What is typical is that with the help of such equipment it is possible to process material simultaneously in 2 or even 3 projections. If desired, you can produce the most complex elements, such as gears, chess, miniature models of cars, various figures, and any decorative ornaments.

Below are the most popular devices on the domestic market, as well as the average market price for them.

FRP-01

This unit owes its enormous popularity to the simplicity of its design and versatility. It is possible to produce molded elements, figures and letters for signs, insulating boards, and so on. The operation of the device is controlled using a computer program included in the kit.

The approximate cost of the unit is 110-115 thousand rubles.

FRP-01 machine for cutting foam plastic

SRP-K "Kontur"

Another wonderful model that allows you to produce various parts for facade finishing and formwork for pouring mortars. The control in this case is manual, but the power consumption is relatively low (about 150V), and it is very convenient to transport.

The average market value is somewhere 42.5 thousand rubles.

Self-production of cutting machine

There are a number of ways to build a machine for cutting foam plastic - from the simplest (hand tools) to the extremely complex ones. Let's look briefly at each of them.

Method one. Hand cutting polystyrene foam

1. The simplest and yet most accessible method is cutting the material with a knife. It is important that the knife used for this has serrations and is lubricated with automotive oil before starting work (this will reduce noise production and optimize the procedure itself). It is also worth noting that this is the slowest of the methods, so it is only advisable in the case of a small volume of material.
2. You can also cut foam plastic with a hot string. To do this, hammer in a couple of nails, stretch a nichrome wire between them and connect the power supply to it. The main advantage of this method is its high speed (one meter is cut in 7-8 seconds) and a neat cut. But there is also a significant disadvantage: such a procedure is harmful to human health.
3. The third method is known as cold wire cutting. In this case, a steel string is used in the same way as a two-handed saw blade. This method is quite productive.
4. In the same way, you can cut foam using a regular hacksaw.
5. Finally, there is a professional hand instrument, finished reminiscent of the hot string mentioned above, only more refined. If you have such a tool, the work is done efficiently and quickly; it is possible to use shaped attachments.

Video - Cutting polystyrene foam with nichrome

Method two. Homemade machine on the table

Be that as it may, cutting polystyrene foam manually, even using one of the tools mentioned above, is quite difficult. The material may burst or crumble, nothing can be done about it. A hot string partially solves the problem, but what if the amount of work is too large? There is a solution - you can build a stationary cutting machine at home.

First, everything necessary is prepared. To create such a device you will need:

• a large table (ideally, each side should be at least 2 meters);
• a string characterized by increased resistance (if you have an old electric heater, it can be removed from it);
• iron springs, which are characterized by low electrical conductivity;
• laboratory transformer (LATR), which converts 220-volt current into 24-volt.

In addition to this, you will also need a string height controller. It could be, say, a pair of beams, and it is between them that the cutting string along with the holder will move.

Note! A transformer is not always required. This moment depends solely on what material was used in the manufacture of the thread. And if it is chrome-plated, then a current of 220 volts can also be used. Although we note that when working with such power, you must strictly adhere to safety rules, otherwise the consequences can be very dire.

If the foam cutting machine operates on only 24 volts, then there can be no danger to the body. You simply won’t feel such a current, and after an accidental injury you just need to rinse the affected area of ​​skin with water.

Let us also remind you that if foam plastic is cut with hot metal, toxic substances will inevitably be released. For this reason, work must be performed exclusively in a special mask, and the room must be well ventilated; otherwise you can get poisoned. Although it is preferable to carry out cutting outdoors, this can only be done if you have your own yard.

To make it more convenient for you to assemble the structure from prepared parts, we have provided below a detailed diagram of the future machine.

Equipment necessary for the production of foam plastic Previously, we talked about the equipment that is necessary for the production of polystyrene foam; in addition to this article, we advise you to read this information

Method three. Homemade machine (in the absence of a suitable table)

If you do not have a table of suitable dimensions, you can make a base for the unit from plywood, regular boards or chipboard. The algorithm of actions in this case should be as follows.

Preparing everything you need

The operating principle of the machine described above is also based on the use of hot metal. If you run a hot wire over the material, it will be easy to cut, and the cuts will be perfectly even. In the workflow, in this case you will need:

The cutting element will be a nichrome spiral. As already noted, it can either be purchased or removed from the old heater. Typically, the thickness of this spiral can vary between 0.5-1 millimeters, although it will be better if it is 0.7 millimeters. As for the length, it depends on the dimensions of the material that will be cut.

Note! An important element is the laboratory transformer. If you don't have one, you can make something similar from an old transformer and a device for charging car batteries.

There is another option - you can take a power supply from a PC, where 12 volt wires (black and yellow) are connected to the spiral.

For a homemade machine, an output voltage of 7-12 volts is sufficient. Another important point is that the thickness/length of the filament must be adjusted to match the voltage. If the heat is too high, the thread may even burst. At the same time, if the heating is weak, the cutting procedure will slow down noticeably.

Finally, the power source can be the car battery itself. This is useful in cases where there is no electricity.

Direct assembly

Below are step-by-step instructions for assembling the unit.

Step one. We take a nichrome thread and attach it to the springs. We put the springs themselves on M-4 screws, and accordingly we screw them into the prepared racks.

Step two. We pre-press the iron racks into a chipboard sheet, tabletop, plywood (or another surface that will serve as a base for a foam cutting machine). The thickness of the base, as well as the height of the racks, should be determined by the needs of the user. With a base thickness of 18 millimeters and a support height of 28 millimeters, the screw, being completely screwed in, will not be able to penetrate through the base; on the contrary, being completely unscrewed, it will be able to cut material 50 millimeters thick.

Note! If in the future we need to cut thick sheets, we will remove the small screws and screw in longer ones instead.

Step three. We make holes in the base for pressing. It is important that the diameter of these holes is approximately 0.5 millimeters smaller than the diameter of the rack itself. Next, using a hammer, we drive the posts into the holes, but first sand the sharp end edges with sandpaper (this will significantly simplify this procedure).

Step four. Before screwing a screw into the rack, take some suitable tool and cut out a small groove under its (screw) head. To do this, we clamp one end with a screwdriver, put a file under the head and initiate rotation. What is this groove for? First of all, in order to secure the wire motionless, otherwise it may move during the adjustment process.

Step five. We fix the wire: first to the springs, and only then to the screws themselves. This is necessary so that it does not sag, heating up and, accordingly, elongating somewhat.

Step six. Having finished with all the fasteners, we take the nichrome wire and fix it. The fastening method we use here is called “crimp twisting”: it allows you to create the most reliable contact between the current-carrying cable and the wire. It is also important that the cross-section of the copper cable is at least 1.45 mm².

Step seven. We remove the insulating layer from the ends of the cables by approximately 2 centimeters. We wind the copper conductors onto the wire where it is already attached to the springs. Using pliers, hold one end of it tightly and wrap it around the conductor. This winding allows for maximum wire-to-wire contact area, and when the machine finally starts working, the connections will not overheat.

Step eight. Next, we make a tap of the conductors carrying the electric current in the form of a loop, so that in the future it becomes possible to regulate the procedure for cutting foam plastic. In addition, we make holes in the base and pass wires through them so that they do not get tangled during operation. After that, we fasten them on the other side using staples.

Note! Experts advise laying the cables together and twisting them, forming a not too tight bundle. In this case, they certainly won’t get confused.

Step nine. We solder the terminals to the ends of the wires that will be connected to the energy source being used.

So, the foam cutting machine is almost ready. Note that the design created according to the above scheme is quite sufficient for home use. Moreover, if desired, it can also be used as a device for shaped cutting of polystyrene foam.

Video - Creating a device for cutting polystyrene foam

1. The cutting process requires medium speed movement of the foam. If it moves too quickly, it will most likely crumble, and if it moves too slowly, the ends of the sheets will begin to melt.
2. If the work is carried out in an area without electricity, then you need to connect 3 9-volt crowns together and use them as an energy source. In this case, the machine will be able to operate for approximately 35-40 minutes.
3. It is not advisable to use car batteries for this, since they, despite their low voltage, also have a high current strength that can damage the string. And it’s also good if it simply bursts, because it may happen that hot metal splashes out.
4. The foam that will be used to insulate the bath must be thick. Moreover, thick material is easier to produce (and it is not particularly popular), which means it will cost less than thin material.

A foam cutting machine is an important element of equipment for many enterprises and home workshops. With their help, the production of various blanks used in construction, repair, decoration, interior design, etc. is carried out.

If you study the range of factory models of machines for cutting foam plastic or simply PSA, then there are several types:

• Mobile. Such PSA are more reminiscent of an ordinary knife designed for working with polystyrene foam with your own hands. With a mobile machine you can make various simple workpieces. Quite often found in everyday life when processing polystyrene foam, expanded polystyrene;
• Machines for transverse and horizontal processing. PSA data is cut in a certain direction, that is, achieving complex figures is problematic. But the machine provides highly efficient production, cutting large materials;
• CNC machines. PSA equipped with a CNC module are modern models of machines for processing expanded polystyrene and polystyrene foam. With its help, you can make machines and 3D models of a wide variety of parameters, complexity and configuration. The current furniture, repair and construction production cannot do without the use of CNC PSA.

Operating principle of the machines

Diagram of a foam cutting machine

If you want to buy a PSA or make it yourself, first you need to understand the operating features of the device.

• The operation of most types of machines for working with foam is based on a single principle;
• The cutting part of the machine heats up and affects the material being processed;
• The cutting element moves according to the drawings;
• The process is similar to passing a hot knife through butter, that is, the process is carried out easily, with minimal damage to the foam or polystyrene foam;
• The simplest model of the machine has one cutting string. This installation is easy to do with your own hands, having at your disposal the appropriate drawing;
• To work with complex 3D shapes and perform high-precision cuts, a PSA with a CNC module is used. The machine itself can have up to 6 cutting strings;
• The advantage of the machine is that additional edge processing is not required due to a clean cut. This simplifies production and minimizes the cost of finishing parts.

Device Features

• If you want to make a cutting device for foam plastic with your own hands, this can be done using two methods - vertical and horizontal cutting of a sheet of foam plastic;
• To make a vertical cut, the cutting line is installed perpendicular to the work table;
• For a horizontal cut, you need to make an appropriate design, the opposite of the first example;
• To get an even, neat cut, you will need a competent drawing and template for subsequent processing;
• The drawing is widely available on the Internet, which allows anyone to make a machine at their own discretion, based on personal needs or materials available for assembling the PSA;
• It is recommended to use nichrome thread as a cutting element. Almost every drawing provides for its use;
• For processing complex parts and obtaining 3D models, the current production of machine tools has reached a high level. Special models of CNC units designed specifically for figure cutting are widely used. The workpiece is processed in several projections at once. Thanks to such equipment, it is possible to establish the production of models of cars, people, airplanes, animals and much more. Moreover, in reality, the resulting 3D products accurately repeat all the curves, lines, and configurations of the copied product.

Making a machine with your own hands

The production of special machines for cutting foam plastic has been put into active production. At the same time, the cost of equipment seems high for many potential buyers. In addition, having the opportunity to assemble a machine for cutting foam plastic without unnecessary help, with their own hands, many simply abandon the idea of ​​​​purchase. The estimated price of a factory machine is from 40 thousand rubles. But there are models costing 100 thousand rubles and more.

Yes, for that kind of money you can get an excellent foam cutting machine equipped with a CNC module. A CNC machine is far superior to homemade simple devices. At the same time, not everyone has a real need for CNC and automated cutting of foam plastic. Therefore, we will give an example of how you can make an excellent unit for processing expanded polystyrene or polystyrene with your own hands. It will not be a bad idea to consolidate your skills with video lessons.

1. Drawing. It is not necessary to use a drawing specifically for a given machine model. It is not needed here, since the design is quite simple. But for clarity, you can draw a drawing yourself, based on the selected parameters. Another option is to choose a drawing for a more serious installation. It all depends on what you want to get out of your foam cutting machine.
2. Select or assemble a table on which to perform polystyrene foam cutting operations. The surface should be covered with thermal insulating or electrical material. Polyamide film has proven itself excellent in this component.
3. Attach the insulator to the center of the long side of the work surface. One on each edge. Ceramic or glass elements can be used as insulators. Between these structural components you will then stretch a thread that will act as a cutting tool.
4. Choose a line. If you have an old hotplate, an unwanted soldering iron or iron, you will find nichrome thread inside them. It has sufficient power.
5. Remove the spiral from the tool, carefully straighten it to form an even thread.
6. It is not recommended to use nichrome threads with a thickness of more than 0.5 millimeters for a homemade machine.
7. Be sure to connect the thread to the network through a rheostat or step-down transformer. This will protect your main working element of the machine from combustion.
8. A nichrome fishing line is connected to a reel on insulating material. An electrical cable is connected to the fishing line, through which power will be supplied to the machine. Try to ensure that the contact between the electrical cable and the thread is as high quality as possible.
9. Under the table, pull the thread to another insulator and pass through it. The end of the thread will hang from the insulator, so a weight should be provided here. The weight of the load determines the tension of the heated thread when processing foam. Here you will have to “play around” a little to determine the optimal parameters of the weight. Movable sliding fixation is the most advantageous when creating such a machine with your own hands. This is due to the fact that this way you will get a better and cleaner cut line, and you will be able to adjust the position of the thread as needed.
10. Near the second insulation coil, a second electrical cable is mounted to the thread, which goes to the rheostat and is connected to the slider terminal.

The machine may only be started after the slider has been set to the maximum resistance level. If this is not done, literally immediately after turning it on, your thread will burn out, and you will have to look for a new one.

The power of the unit depends on the current parameters and the thickness of the thread used. The only drawback of a homemade machine for working with foam plastic is that when heated, the material emits an unpleasant odor and harmful substances. Therefore, it is strongly recommended to use the machine only where there is an effective ventilation system.