[SML] Wire foam cutter

[Dougherty, Jim]

We’ve done a few different things over the years:

For short sections, we’ve used nichrome wire and a transformer to follow a pattern of the cross section of the molding; the maximum section length was about 4’ and the sag in the wire going through wasn’t so bad that the profiles wouldn’t match, but it’s there.  The wire was on a frame that used a spring to keep tension on the wire as it followed the pattern and kept the wire parallel to the axis of our piece.  As for the product, think crown molding with an ogee curve or two, maybe 7”x8” in cross sectional area.  This video shows a similar process: https://www.youtube.com/watch?v=Ombv3lS4fS4

We’ve also used plumbers’ tape and banding steel bent to the profile we wanted, then fed the Styrofoam sections past it.  Balancing the power so that it was hot enough to cut without overmelting foam or softening the cutter steel, and not too cold so that the force of feeding the foam through was tricky.  We were able to make longer sections, though.

For the latter we used a welder to supply the power.  For the former, we used a transformer and insulator/spring kit from Demand Products (https://www.demandproducts.com), who sell a wide variety of foam cutting and shaping tools for the architectural scenery field (i.e. that sweet molding isn’t carved stone, it’s foam with stucco on top).

Hope this helps, and remember all the safety steps like respirators, ventilation and the potential for a nasty foam fire!

Jim Dougherty
Co-TD/Facility Manager
Middlebury College Theatre Dept.
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