1 2 3 4 5 6 7 8 9

Open Source Foam Cutter

E

4 axis, cheap, modular CNC hot wire foam cutter

Ver. Desc. By Date

0.2 OpenSCAD version R. Lodde 22-10-15

 1 2 3 4 5 6 7 8 9

Specifications Key features

F
This machine cuts foam (EPS, EPP, etc.) by moving a hot wire. The The main goal was to achieve the highest possible precision while
wire is suspended between two frames, each with two independent keeping the overall complexity and price low; this drove the design
axes. The picture below shows the axes arrangement and the in the following direction:
directions used in this document.
- The wire is supported by an arc which is not part of the main
frame: the wire tension doesn't pull on the guides but is
completely on the arc itself.
E

- After some iterations, we opted for an arc built in a way that all
the forces are converted into tension on a surrounding wire. This
allowed to reduce the structure size and weight, further reducing
Rig the load on the frame.
ht
Back
A - Once off loaded of almost all the forces, the frame can be built
D with light, cheap and easy to work 20*30mm wood profiles.
B
- To reduce assembly time and skills required, we made extensive
use of multi functional 3D printed parts. The only specialized tool
we advice to use is a drill press for making the holes in the wood
Le

nt parts.
Fro
ft

Z
C - The control system is based on components such as pulleys, belts
X Y
and linear bearings that are widely used in the DIY 3D printers;
Having four independent axes allows to cut also non square objects there is a huge market for those parts and they are relatively
like tapered model airplane wings. cheap and easy to source.

The work area is 650x440x1200mm. However, it's very easy to The design is released under the GNU GPL v2 license.
change the Z lenght by assembling the machine using shorter (or
B longer) spars. Lesser Z means better accuracy when cutting small
parts and also greater taper angle possibilities. The tempered steel
shaft are also oversized, it's possible to build bigger machine just
using longer rods and frame elements.

It is also possible to implement a 5th axis, a rotating plate on the

XZ plane. The option is absolutely feasible from a mechanical point
A of view but it's not implemented yet.
Open Source Foam Cutter
Scale n/a

OSFC 0.2 Page 2 of 22

 1 2 3 4 5 6 7 8 9

Anatomy
F

All the actuator and electronic systems are mounted on the side
frames.
Arc guide
The wire support arc holds the cutting wire resting on the two
vertical carriages. The extra lenght is necesary to compensate
Wire support arc the distance increase when doing tapered cuts.
E
Frame joiners
The arc guide is necessary to avoid the arc falling when the Y
and / or B axes rise.

The cut bed has the only purpose to hold the material at
working height. It's nice to have reference lines on it every 5 cm
because some cuts require to place the material at a given
D
distance from the towers. Size is 1200x730x120 mm. The
Cut bed reference guides distance is 50mm.

The wire current is controlled using a RC battery charger

(iCharger 106 B+) that has a dedicated function. The best way
to control the wire temperature is to work in constant current
mode, it will give more or less the same temperature even if the
C wire length changes.

The motion control runs on a PC and a DB25 interface port from

Right frame
ebay.

Left frame

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 3 of 22

 1 2 3 4 5 6 7 8 9

Cut the raw materials

10 mm
F
800 mm

130 mm
Arc backbone holes template(both sides)

15 mm
Top (2x)
d = 5 mm
E

650 mm
Back (2x) Front (2x)
8 mm

27 mm
D Bottom (2x) Arc sides

730 mm
all holes d = 3 mm

1700 mm

B Arc backbone (1x)

10 mm
1320 mm

Z joiners (4x) Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 4 of 22

 1 2 3 4 5 6 7 8 9

Front frame element drill template

F

top bottom
8 mm 10 mm
8 mm

15 mm
22 mm
40 mm

d = 5 mm
D
75 mm

100 mm
d = 4 mm
d = 5 mm

89 mm
C

75 mm
65 mm
47 mm

40 mm
33 mm
B

10 mm

A
All holes d = 3 mm unless otherwise specified
Open Source Foam Cutter
All holes on center line if no horizontal quote is present
Scale 1:1

OSFC 0.2 Page 5 of 22

 1 2 3 4 5 6 7 8 9

Back frame element drill template

F

top bottom
8 mm
8 mm

15 mm
22 mm
40 mm

d = 5 mm
D
75 mm

100 mm
C d = 5 mm

65 mm
47 mm
33 mm
B

25 mm
8 mm
A
All holes d = 3 mm unless otherwise specified
Open Source Foam Cutter
All holes on center line if no horizontal quote is present
Scale 1:1

OSFC 0.2 Page 6 of 22

 1 2 3 4 5 6 7 8 9

Top and bottom frame elements drill template

F

42 mm

24 mm
D
d=10 mm

5 mm
C

Note: countersink hole in the

bottom element only.

A
All holes d = 3 mm unless otherwise specified
Open Source Foam Cutter
All holes on center line if no verticall quote is present
Scale 1:1

OSFC 0.2 Page 7 of 22

 1 2 3 4 5 6 7 8 9

Side frames assembly

F

Make sure is flush

3x50 self
tapping screws
E

C
3x50 self
Screw sink goes inside
tapping screws
when the frames are joined
make sure they are mirrored

B Bottom elements
holes towards front side
25 mm

A
Note: all the images in this document refer to the left panel.
Open Source Foam Cutter
Scale n/a

OSFC 0.2 Page 8 of 22

 1 2 3 4 5 6 7 8 9

Horizontal guides installation

F

Prepare the 12mm shafts with 5mm wide washer

bearings and supports
M5x45

M5, self locking nut

E

Do not overtighten!
Once the washer
slightly
marks the wood is OK
D

Install the supports

flush to the wood
horizontal Pay attention to the Pay attention to the
elements . The belt supports End stop support lid reduction gear
ABS parts have orientation: on the same side as holes position
B enlarged holes to the belt tensioner the counersink hole in
accommodate slot goes the frame
tolerances in the outside.
wood frame.

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 9 of 22

 1 2 3 4 5 6 7 8 9

Horizontal drive installation - part 1

F

M4x45
E

Mount the screw

in the countersink M4x40
hole first M4x40
Install the motor support

M5 nut F625 bearings M5 nut - use heat

and / or glue to fix it
Overall view
C

20 mm

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 10 of 22

 1 2 3 4 5 6 7 8 9

Horizontal drive installation - part 2

F

Slide in the pulley M5 self locking nut

from the top tighten so it barely
touches the bearing
E

Tighten very lightly

avoid useless stress
on the bearings
5 mm
small washer
F625 bearings
D

Tighten firmly
5 mm
(do not crack the plastic)
wide washer

C M5 self locking nut 3 small washers

keep the bearing
in place

Slide in the upper

support group and pulley
and bolt it to the frame
B

4 mm
M4 self locking nut washer

M4x40
A

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 11 of 22

 1 2 3 4 5 6 7 8 9

Vertical guides installation

F

Install the upper

carriage.

Install the lower carriage

making sure that the
end stop support is towards
the AX end stop.
D

Slide the shaft through

the upper carriage, insert the
bearings, slide through the
C lower carriage until they rest
on the stepper motor face

M3x10 socket head screws

Install the motor before

sliding in the 8mm shafts

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 12 of 22

 1 2 3 4 5 6 7 8 9

Horizontal drive installation - part 3

F
Install the screw pins in the upper
and lower carriages where the
belt will lock to. Do not over tighten
or the plastic might crack
Pre set position:
Tensioner inside guides 5mm

E M4x25 M4x20

624ZZ bearing

M4 nut
M4 blind nut M3x20

C
Hot glue

GT2-18 M3 self locking nut

B
3mm washer
GT2-99

M3x10
A

Open Source Foam Cutter

Scale n/a
GT2-260mm
OSFC 0.2 Page 13 of 22
 1 2 3 4 5 6 7 8 9

Horizontal drive installation - part 4

F

Insert the belt from the

outside, teeths inside

Lock the belt on the screws using

two zip ties on each side

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 14 of 22

 1 2 3 4 5 6 7 8 9

Horizontal drive main belts setup

F

Make sure the 18 teeth pulleys are free to move

before starting.

1) check that the 8mm guides are vertical and

E parallel to the frame. The parts are not on the
2 same plane, using a wood block as reference
helps.
3 4
2) ensure that the pulleys are at the right height
and the belt is straight

D
3) adjust the belt tension: since the machine
moves very slow, it doesn't need to be super
tight. Be careful to not bend the 5mm shaft.
1
4) double check the measurements and tighten
the pulleys set screws.

4
3
B

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 15 of 22

 1 2 3 4 5 6 7 8 9

Vertical carriage preparation

F
27.5 mm

5 mm 5 mm
12 mm

6 mm
Bevel the edges so the
wire will not jam when
cutting at high angles

55 mm
D

C M3 nut

M5 nut - use heat

to insert
M3x10
A

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 16 of 22

 1 2 3 4 5 6 7 8 9

Vertical carriage installation

F

M5 Nut Slide the 5*520 threaded rod through the upper carriage,
screw through the cursor and fix it to the flexible joint. Insert
the flanged bearing on the upper carriage and screw in the
retaining nut - it has to be tighten so it just touches the
bearing.

F625 Flanged
ball bearing

M5x520

5x5mm flexible
joint

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 17 of XX

 1 2 3 4 5 6 7 8 9

Main assembly
F

20x30x1320mm wood beams

add diagonal cables

to increase frame rigidity
3x40 self
C tapping screws

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 18 of 22

 1 2 3 4 5 6 7 8 9

Wire support arc assembly

Arc guide slider
F
M5x35
M5 Self locking nut
Joiner washer on both sides

Glue
Tension strut at 16 mm
E

Nail M3x35
M3 self locking nut
D
washer on both sides Press fit

C
Tension cable
The cutting wire must be
electrically isolated from the
supporting arc

B
20x30x1700 wood beam

10x10x730 aluminium beam

A
Note: the wire must be installed
Open Source Foam Cutter
when the arc is already on the main
Scale n/a
machine frame
OSFC 0.2 Page 19 of 22
 1 2 3 4 5 6 7 8 9

End stop installation

F

xx

Microswitch

Actuator

C 3mm threaded rods

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 20 of XX

 1 2 3 4 5 6 7 8 9

Generate the STL files

F
The STL files are not distributed directly, it's necessary to generate STL creation workflow:
them using OpenSCAD: an open source, multi platform, solid 3D
CAD modeller. Download it from: - Select the parts setting the render flags
- Preview the result
www.openscad.org - Render the result
- Export the STL file using the file - export - export as STL
Download the file OSFC-Oscad-0.2 and uncompress to a command.
E convenient location. Install the OCR-A fonts since they are used to
generate the logos on the parts. We recommend printing the calibrator part first, check that the
tolerances are OK and then go ahead with the other parts. The
Open the file OSFC-0.2.scad OpenSCAD file has comments that explain how to tweak the
parameters.

Screw and bolts

screws should go
LM12UU slot
through free, bolts
should fit tightly

Zip tie channels

LM8UU slot
B

Tempered shafts slots

look for a tight fit

A Render

Render flags Preview Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 21 of 22

 1 2 3 4 5 6 7 8 9

Hardware Store CNC Hardware Store 3D printed parts

Item Description Qty Item Description Qty Item Description Qty

1 3x50 self tapping screw 16 31 12x800mm tempered steel shaft 4 61 Tempered shaft support - LF 2*

2 3x40 self tapping screw 16 32 8x550mm tempered steel shaft 4 62 Tempered shaft support - LR 2

E 3 M5x45 socket head screw 16 33 LM12UU linear motion bearing 8 63 Tempered shaft support - HF 2

4 M5 x 15mm washer 26 34 LM8UU linear motion bearing 4 64 Tempered shaft support - HR 2

21 M5 x 10 mm washer 8 35 F625ZZ flanged ball bearing 10 65 Reduction gear support 4

5 M5 self locking nut 26 36 6254ZZ ball bearing 4 66 GT2-2mm 99 teeth ABS pulley 2

6 M5 nut 6 37 5x5mm flexible joint 2 67 Belt Tensioner 4

7 M4x40 socket head screw 8 38 GT2-2mm 18 teeth aluminium pulley 6 68 Stepper motor support 2

D 27 M4x45 socket head screw 2 39 0.8A Nema 17 stepper motor 4 69 AX Carriage - low 2*

8 M4x25 hexagonal head screw 4 40 Micro size switch 4 70 AX Carriage - high 2

9 M4x20 hexagonal head screw 4 41 6x260mm closed loop GT2 belt 2 71 BY Carriage 2*

10 M4 nut 4 42 GT2 belt, 1600mm 4 72 End stop actuator 4

11 M4 blind nut 4 74 Arc Joiner - 20x30 4

12 M4 self locking nut 10 75 Arc tension strut 2

C 13 M4 washer 6 76 Arc reference plug 90° 1

Miscellaneous
14 M3x10 socket head screw 18 77 Arc guide slider 1
Item Description Qty
15 M3x20 socket head screw 8 78 Arc guide foot 1
91 20x30x800 wood side frame top 2
16 M3 washer 10
92 20x30x800 wood side frame bottom 2
17 M3 nut 8
93 20x30x650 wood side frame front 2
18 M3 self locking nut 10
94 20x30x650 wood side frame front 2
B 19 M5x660 Threaded rod 2
95 20x30x1320 wood frame connectors 4
20 M5x520 Threaded rod 2
96 Cutting Bed 1
23 M3x35 Socket head screw 2
97 Wire support blade 2
24 M5x35 Socket head screw 4
98 20x30x1700 wood arc main beam 1
25 Soft steel nails 2
99 10x10x730 aluminum arc sides 2
26 M3x45 Threaded rod 4
100 6x650mm carbon fiber arc guide 1
A

Open Source Foam Cutter

Scale n/a

OSFC 0.2 Page 22 of 22