Maker Station equipment
Hot-wire
cutter
A Styrocut 3 benchtop machine that uses a heated wire to shape polystyrene foam. It has an integrated fan that draws fumes away from the cut.
Training and hours
The hot-wire cutter is introduced as part of the 3D printing and 3D scanning workshop route. View the workshop route.
It is a basic manual machine. Use only the method shown during the workshop.
The machine is a Styrocut 3. Setup and cutting take place during staffed hours.
What it can cut
The size of the machine sets the limits of the work. Plan the piece around them, and cut a larger form in sections rather than forcing it past the frame.
| Measurement | Limit |
|---|---|
| Opening width | 460 mm between the wire and the guide bar |
| Cutting height | Adjustable in six steps from 80 to 205 mm |
| Angled cutting | Up to 45°, usable to a cutting height of 130 mm |
| Working surface | 610 × 265 mm |
The wire is controlled with a pedal switch, which leaves both hands free to guide the foam. A protractor and steel ruler are kept with the machine for setting the guide bar and the cutting angle.
Using the cutter
- Check that the wire is intact and correctly tensioned before switching on.
- Let the wire reach temperature before starting the cut, and move the material steadily rather than forcing it.
- Keep fingers away from the wire, which stays hot after the power is switched off.
- Support long or thin pieces so they do not twist into the wire.
- Switch off and let the wire cool before changing or adjusting it.
Materials and ventilation
The machine is made for expanded and extruded polystyrene, sold as Styrofoam and Styrodur. Cut only foam approved for this machine.
Switch the integrated fan on before cutting. It draws the fumes away from the wire, which keeps the smell down and gives a cleaner cut edge. Use it together with any additional ventilation shown during the workshop.
Never cut
- PVC foam, which releases corrosive and toxic gases when heated
- Any foam or plastic that cannot be identified
Ask staff before using coated, laminated or adhesive-backed foam, or a material not already approved for the machine. Heated cutting releases fumes from many plastics.
Safety
- Use the ventilation arrangement demonstrated during training whenever the wire is heated.
- Keep fingers, hair, clothing and tools clear of the hot wire.
- Do not touch or adjust the wire until the machine is switched off and the wire has cooled.
- Stop if smoke increases, the material ignites or the wire becomes loose or damaged, then alert staff.
- Do not process an unidentified foam or improvise a material test.