Hot Wire Foam Cutter (and jigs) for professional model makers - styro slicer

A hot wire foam cutter / styro slicer is a great addition to the workshop, useful for prototyping, mold making for concrete and modeling with foam.
I have created a feature rich and versatile hot wire foam cutter with a bunch of jigs to assist in creating exceptionally accurate hot wire cutting.
This hot wire foam cutter includes; an inbuilt LED light, adjustable angle arm, Volt and AMP meter display with adjustable volts up to 15 volts allowing the temperature to be precisely controlled. additional port for hand held accessories, circle and cone cutting jig, 45 and 90 degree with set stops jig, the never seen before quick change straight edge jig, thin rip fence jig, and fence, quick release tensioner, quick wire clamp release, micro adjuster for setting up the nichrome wire to 90 degrees accurately, foot pedal operated. and a bunch of other neat functional and design features.
The foam cutter / styro slicer has a high level of precision and with the innovative straight edge jig you can get very precise straight cuts even in odd shaped scraps of foam.
Building your own hot wire foam cutter / syrup slicer is relatively easy , there will be a build video that follows, this will include wiring diagrams and details of all the electronic parts used with a good overview of the steps to build the whole hot wire cutter.
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Music by: David Cutter Music - www.davidcuttermusic.co.uk

[@RANDALLOLOGY]

That is the most professional looking foam cutting machine I have ever seen built. Excellent job sir.

[@PhilHarlow]

At first it seemed a little overbuilt, but as you walked through the features it's really awesome, well designed, and very effective!

[@StuffIMade]

Phil Harlow thanks! I do have a tendency to overbuild things so probably some truth to that ! ;)

[@BernSha]

Great stuff! The only offer I have is to have you reconsider the need to apologize for being perfectionistic. The high quality and level of precision you bring is actually what makes your build most attractive. The cutter is an artistic self expression of who you be in the world. If you have to apologize for who you are then you might as well pack it up. Again, great work and thank you for the value you are and give so generously!

[@StuffIMade]

Very kind words!!!!

[@michaelgasperik4319]

This is by far the best hot wire build I've seen!

[@rolfschubert1853]

I love the attention to detail. This is a well thought out and well built machine. Thank you for showing the functionality before forcing us to sit through the construction of something we've not seen in its entirety. This is how all build videos should be done. You have made a subscriber out of me.

[@StuffIMade]

Rolf Schubert thanks! I’m about to start doing more videos after over a year off ;)

[@robertjirava942]

Extraordinary. Very well done. Best foam cutter I have ever seen by far. 10/10 !!!

[@nurabdul1436]

The Rolls Royce of foam cutters!

[@gt500mike-8]

I just ran across your hot wire cutter & love it. As for making lock for the slide board when making cone cut. You solved the problem already. Use the top of fence for locking a removal fixture. The removal fixture would be a strip of wood the length of slide board & height of distance from slide board to top of fence & two short dowels on bottom that would fit into slide board holes. Then attach another piece of wood to top side of dowel piece to make an over hang on fence top with same locking slot you used on slide board before. You posted this video a long time ago & you probably came up with this same idea already. But if not here it is. Thanks

[@ownpathcreative]

Wow. I’m so inspired to make a similar one. I can’t believe it has so many wicked features.👌🏾

[@mreid08]

If this was a infomercial I would have bought at least 3 of them, this is a nice cutter!

[@BillKibby1]

I have absolutely no use for a foam cutter, whatsoever... Strangely after watching this I feel drawn to my workshop to emulate this :) Very nicely executed project, well worthy of a sub! Carry on! - Bill

[@StuffIMade]

Bill Kibby strangely I have no use for one either ;) just wanted to make one, but the best one I could think of. Glad you liked it !

[@BillKibby1]

HAHA!! That just made my day, thanks! My pet project right now is a PWM controller designed for use with a computer power supply. Did you know a piece of nichrome wire can easily illuminate a small room? :~) Hoping to release it soon to the pyrography crowd though it should work well for a foam cutter or plexiglass brake. Any thoughts on producing any more of these and selling them?

[@StuffIMade]

Bill Kibby sound like great project. Will there be a video ? thinking about putting this one on eBay will the jigs etc.

[@etruedus]

Another rabbit hole I fell down into(simply don't know how I got here), but I am super glad I did! You have a great talent for engineering and fabricating, as well as a new subscriber.

[@Discipol]

I want to buy this. The craftmanship is amazing, design simple but functional! My only nitpick is no gradation on anything but I would still buy this!

[@StuffIMade]

Discipol thanks! The reason for no gradation is because if I want a specific angle I want it to be highly accurate, so I prefer to make angle templates to slide up against the wire to set my angles. I think probably for what I do 3 or 4 angles suffice. The variance in the wire when adjusted to 90° and the accuracy of locking the arm at a set angle repeatedly required more effort to be totally accurate so I opted not to do this. But I get where you are coming from!

[@thefunbot]

a wonderfully engineered cutter - best i have ever seen

[@viannajorge]

That’s the best I have ever seen!!! English is not my native language... I will watch sometimes and try something similar! Really excellent job!!

[@StuffIMade]

thanks for the kind words!!!

[@Terranscapes]

Fantastic build. Seriously. I love the dedication to form and function. It has now driven me to create some jigs for the hot wire table I already have. Worth the watch alone. Thank you for sharing your project and your passion.

[@StuffIMade]

Terranscapes thanks very much for the kind words!!!

[@rachelandjayshared342]

Wow this is art! Best foam cutter I’ve seen. Want one!

[@Acheiropoietos]

I was going to ask about making an angled wire cutter and you demonstrated just that! Really neat, accurate design.

[@CarbonKnights]

That's the Ferrari of hot wire tables right there.

[@thoughtsy]

Awesome! It really seems to be the ultimate hot wire foam cutter system.

[@pksangal4935]

Extremely functional design, looking forward to detailed build. Hope it is soon. Thanks

[@jafinch78]

Thanks for sharing. Best most versatile build I've seen for one of those.

[@geoffmeston1814]

Thanks!!

[@mahimac8126]

Awesome build! Hands down one of my favorite I have seen. Its a very well thought out build. You use materials like the aluminum extrusion, custom knobs, and electrical components that aren't used as often. The build is very professional looking and built very well. Can't wait for all of the videos detailing how to make it. Thanks for the great content. For the build video please if possible include a list of materials and where to buy. It would be great help. Again thanks.

[@StuffIMade]

Magdiel Rodriguez thanks! I will do my best on the parts list!

[@roedyhellyeah]

so, i found this video 4 years after uploading, looks great wonderful inspiration. sad to see there are no video's on the hand held tools

[@skrawn1342]

By far the best design/concept I've seen!!

[@StuffIMade]

SKrawn 128 very kind of you to say ;)

[@Georges-MILLION]

Très belle réalisation ! De plus , très belle démonstration ! Merci du partage . Very nice achievement! In addition, very nice demonstration! Thanks for sharing .

[@StuffIMade]

merci beaucoup!

[@gamunujayasinghe3829]

Great video . Sir , thank you so much for shearing your knowledge . I am from Sri Lanka .

[@tufedw19]

That is an awesome hot wire cutter, that is some top quality workmanship. I saw videos on hot wire cutters some time back and was thinking of building one then was thinking of just what you did. I was going to add measurements both inches and CM. I would say make a build pamphlet, that could be sent via e-mail for for like $10 or so. Or maybe even figure up the material cost, to include shipping for mail orders. Like some of the others I can't wait to see your build video on this, that is a beautiful piece of equipment.

[@anthonytiballi5412]

Ed T A

[@thefrenzel]

What a wonderful build! Amazing workmanship. (That upside-down power button though... 😄)

[@StuffIMade]

Frenzel Ano yep total oversight ;) sorry about that! Has been rectified now. 😭

[@fargrim517]

Great work!!! Makes me think to make jigs for my proxxon table.

[@GregsGarage]

Wonderful project. I really like all the jigs that go with the cutter.

[@StuffIMade]

Greg's Garage thanks dude!

[@Heptode]

Excellent project. Great accessories; and a good demo showing how to use the machine.

[@StuffIMade]

Heptode thank you 😊

[@donfillenworth5702]

Very nice! I'll be watching your other videos.

[@StuffIMade]

I will making more in a month or too

[@simezra]

this is amazing, really you should sell them! fantastic work man

[@zzis4me]

Fantastic! Can't wait to see the build video.

[@zibakhan9867]

Wow super cool.... love the foam holder. I wana make one

[@adamnissan3903]

Very very neat unit. Thank you for uploading

[@StuffIMade]

adam nissan cheers !

[@stevewalker7822]

I like the concept of this tool, and I'm looking forward to the build video.

[@StuffIMade]

steve walker thank you!

[@lorrainebijou4108]

Fabulous build and would come in extremely useful in building cosplay costumes out of foam. Would definitely cut down on cutting time.

[@ejspinn]

Wow amazing work done on this machine! You are the ultimate craftsman!!

[@StuffIMade]

ej spinn very kind!

[@tymcbride3477]

Whatttttt!!!!! Did you make this all???? Soooooooooooooo good!!!!!!!!!!! YOU HAVE SOME SKILL AND DESERVE MORE SUBSCRIBERS!!!

[@StuffIMade]

Ty McBride ahh man thanks for the kind words dude!

[@zanfozanfani]

Really super job. You should make it as a job and put it for sale

[@rodneygreenway]

Very informative I intend to make so mods to mine after watching this vid

[@ErgonomicChair]

I am worried I miiiight not have the electrical skills for this one.The spring loaded area is a bit tricky looking too... but I do have a journeyman welder on my side lol.

[@nevillecreativitymentor]

Thank you fo the amzing video Hope to build this early 2026 (just saying its going to happen)💪

[@StuffIMade]

Make a video of your build and tag me ;)

[@nevillecreativitymentor]

@@StuffIMade most certainly. Cheers

[@JerryCalverley]

Excellent workmanship. Love your detailed and versatile design.

[@albertoalhadeff5146]

My friend, it is simply perfect 👍🏻👏

[@MakesCrap]

This is a fantasic job! I love all the jigs! I may end up copying some of your designs

[@josephdunlopburns8225]

That is tip top, well done sir 👏

[@davidlindfield]

Great video and brilliant build. I've been looking for ideas and yours is the best!

[@a68riz]

Beautiful work! Thanks for sharing

[@robertcoulson483]

Excellent!

[@cliftonsnider1520]

Well you earned my subscription. Great video and a very high quality machine.

[@VIAPICCINNI]

BRAVO!!! PROFESSIONALE

[@shenawix]

Very professional, why you don’t fabricate and sell ? I’d pay for such product 👏👏👏

[@tratiyabhavesh]

Excellent job Great

[@geraldhector2743]

Great work.

[@StuffIMade]

Thanks Gerald!

[@pacoryu]

Awesome job man!

[@RiccardoBenussi]

Simply awesome 👍🏻

[@StuffIMade]

Riccardo Benussi thanks 🙏

[@Rustbukkit69]

You Sir, are a genius!

[@ChooseyourownpathWoodcrafts]

Hey from Canada ,,,, love it great job

[@cevdetable]

one of the best ever

[@Cactusworkshopchannel]

man this is super fancy!! awesome!

[@StuffIMade]

Cactus! workshop thanks for saying so!

[@hebrewhammer1000]

Great video! Thanks for sharing.

[@bobkeller8383]

Very nice. I want something like this

That looks great! Well done mate!

[@StuffIMade]

Tuomas Soikkeli thanks dude, I have really poor audio and I rushed editing the video to get it out before my holiday! so apologies for that!

[@YknotLearnall]

A fine build for sure and one of the nicer ones I've seen. Love the LED lights. Switches and read out. Use of extrusion was smart. But... I see a couple things right off I question. First, you can't raise the center arm. At least not without replacing and rewiring. Secondly is your design for creating angles. And this just going by watching the video mind you. You have a center hole and the bottom wire fixed to a point under the table. Once you move the center arm off a 90° angle... the bottom fixed point gets raised and moved to the side of the upper hole in the table face. This will though off the bottom center point by a mil or more. Using your circle gig, it would be thrown off even more since you have what.. ? an 1/8" or better slot for the wire to feed through... So say you're cutting a 100mm circle. At 90° your center pin is on mark. Once you go off 90° on the center arm, the center pin is no longer aligned to center of the wire in one direction or the other depending on which side you come at it from. I'm sure adjustments can be made or it compensated for.. or I could be wrong entirely. From your video it's just something I noticed. I've seen others where the arm is basically a U hiding the wire on both ends. The pivot point in the arm keeps the wire, no matter the angle, at center flush with the table top. Mind you, it's still a beautiful build. No question. Those are just a couple things I noticed that may or may not be able to be improved. or redesigned if needed. Thanks for sharing. I'll definitely be taking some aspects of your build away for my own. cheers...

[@StuffIMade]

chase thanks for the comments and praise! The thing about the angle and pivoting above and below the table was something I considered, but decided when I put the circle jig on the table and tilted the arm I would used a digital protractor to be certain the angle of the arm was accurate, also a small rule to ensure the distance from the circle centre pin. The level of accuracy I wanted from the system was going be very difficult to not have some form of set up and checking anyhow. But yes I agree certainly room for improvement for sure!!!! Thanks again ;)

[@geoanalyst925]

Fantastic great work. Thanks!

[@grantkinnaird1861]

A marvelous design. Are you considering manufacturing the cutter? If so I'd seriously consider buying one. Dependant on price of course.

[@StuffIMade]

Grant Kinnaird thanks! No plans on production. Not sure it would be financially viable. What would be a fair price?

[@dondecaire6534]

Very impressive, well done.

[@angelogunatilaka1740]

Well detailed video, thanks for sharing your ideas👍👍

[@scrambledcitycustomz8134]

Awesome stuff!

[@StuffIMade]

Thanks dude!

[@easy_3d]

Best foam cutting machine on KZbin i guess...loved it...what is the gauge of the nichrome wire you used?

[@StuffIMade]

28gauge

[@Cachaloteman]

Really good job...Congratulations

[@AndreiIR000]

Wow! Just wow.

[@StuffIMade]

Cheers

[@JamesRPatrick]

Very nice execution.

[@wjcm8883]

This hot wire foam cutter is a sterling testament of OUTSTANDING ingenuity and craftsmanship on the part of its creator/builder! Can you provide advice/tips for constructing a similar device that can be used to cut foam wing cores (airfoils) of varying lengths up to 48 inches (including 'twist" - wing washout from root airfoil to tip airfoil)? Bill Jackson.

[@StuffIMade]

William Jackson thanks for the kind comments! Do you have pictures of the elements you are trying to create?

[@wjcm8883]

Yes - I will upload photos of a foam wing airfoil for a Beechcraft Bonanza radio-controlled model airplane. The foam core consists of three individually cut segments to accommodate a tapered leading edge and "twist" wherein the root airfoil is at -5 degrees, and the tip airfoil is at 0 degrees. I'll try to get photo shots and upload same to you within the next 2 hours or so.

[@DroneFun]

Fantastic !

[@galendcia]

great tool ... i like it, i want to make it

[@yogeshdarlinge4276]

Hi, your stuff is absolutely brilliant piece of work. I really like it and want to make same. I have gone through the videos, which describes the process of making. Can you please share the circuit diagram and list of components used in this? I will highly appreciate if you do so.

[@StuffIMade]

Yogesh D I made two videos on the build of this, both are on my KZbin channel. The second goes into detail on the electrics. This is all I have, no diagram sorry, but there may be a parts list in the comments section of the second video.

[@arturzyx]

Wonderful! Inspiring work! ✨

[@JakeSpeed1000]

Very nice!

[@sathishrao5233]

wonderful project

[@FJR-ie7dk]

Very good job If I need one how much cost me in dollar. Thank you

[@marble_wraith]

nice build, this gives me some ideas.

[@vishalgondi3982]

Superb, very very beautiful design 👌, Really appreciated 👍😀👌, May this cut pu foam ??

[@Mukundanghri]

Great advancement. I'm sold. Where can I buy?

[@randyl9071]

Brilliant!

[@DavidsProfession]

nice

[@sostutosos]

Magnifique vidéo

[@jerobleda]

Excelente máquina, muy profesional

[@scrambledcitycustomz8134]

Wow great stuff!!

[@nathans.4332]

What are the locks that you use for the fence called and where did you get them, or how did you make them? And this is probably one of the best tables I've seen. Definitely in the top 3, great work.

[@StuffIMade]

I combined a couple of things, this type of clamping handle (amzn.to/2GLT7fj) and this type corner bracket (amzn.to/2J4tpYs) along with aluminium t-slot nuts. I did actually manage to find these corner brackets but with a hooked edge so i only needed one t-slot nut per side, unfortunately i cant find them to share with you but the links i shared should solve your need. Thanks for the kind comments :) i think maybe top 2 - lol

[@TroyMountain]

Stellar!

[@JimCoogan_CoogansWorkshop]

Excellent work. Would definitely make a great addition to any shop. I look forward to the build video. Did you plan to create a written plan for it? I would be interested in that if you do. Excellent video but the sound was a little low.

[@StuffIMade]

no written plan sorry! build video and wiring diagram to follow! sorry about the sound, i need to get a mic that clips on to me!

[@JimCoogan_CoogansWorkshop]

Thanks. I really like it and am thinking about building one. I like to model things I am building.

[@JohnMartinBradleyStuff]

I really enjoyed this video, thanks so much. You are a f%$£ing genius! I've liked and subscribed.

[@StuffIMade]

John Martin Bradley that's what I have been telling my wife but she just laughs at me!

[@bikboklv]

Great machine

[@StuffIMade]

bikboklv thanks very much!

[@TheSmallWorkshop]

You don't need the clip attaching to the nicrom wire. Use the aluminium rail as the current lead. It is already conected to the nicrom wire right now, you just have to connect the electricity to the rail.

[@StuffIMade]

The Small Workshop true, I want to be able to cut this circuit off when using hand held device through the additional port. Avoiding another switch. But food for thought thanks!

[@djordjeeric9262]

Wow good job sir

[@bobdickweed]

Bloody great mate...really good build...well doe man...;-p

[@StuffIMade]

Eye Toldyoosso very kind of you to say so sir!