Here’s an interesting homemade tool – a bandsaw-like table where the blade doesn’t move, and is instead a heated hot wire for cutting foam blocks like you would move blocks through a bandsaw. Love it! I’ve made hot wire cutters before but only ever the handheld kind that allow for more freeform movement. This design however is much better suited to bigger blocks or frankly straighter cuts (as long as the side laying down is perpendicular and flat):
Hey guys, I am working on some foam models right now and needed to be able to cut larger pieces of foam so this weekend I designed and built a hot wire foam cutter table.
I wanted to share the process because it’s a really easy weekend project and it cut through 5 layers of glued together foam sheets like butter! You’ll end up with a powerful tool that will help speed up your foam modeling. This version can cut make cuts up to 28″ tall and 16″ wide but you can adjust it to be as large as you want. You can cut horizontally or vertically, it’s easily adjustable with the corner clamp on the arm that holds the wire, and the hole thing breaks down and fits in the base.