The art of hotwire

I love airfoils. Just love the smooth curves that produce magical lift. Here is a moody contemplative video celebrating the art of hotwire cutting.
My seup is working smoothly now with 4S lipo power and templates of thin aluminium flashing, cut out with scissors. The wire is 40kg 7 strand SS fishing leader wire.
Template material is 0.3mm aluminium window flashing - www.bunnings.co....
The Yellow foam is Knauf XPS insulation foam - www.bunnings.co...
My hot wire setup - • Hot wire airfoils and bow
MATERIALS
All my building materials and RC gear - newtonairlines.......
Yellow foam - Knauf XPS insulation foam - www.bunnings.co...
Bulk Depron - www.tradewareho....
Skyshark P4X spars - www.kitesandfun....
New Stuff iron-on film - EZload laminate - www.neopostonli....
Blank ID cards - Ebay www.ebay.com.au....
Newton Airlines blog (Plans) - newtonairlines....
Website - anewton.net
Music - deleted due to copyright claim

[@MickB235]

I played it a few times just to listen to the music. I rarely like backing tracks to this type of video but this is an absolute utmost exception

[@AndrewNewton]

+cyclistpilot UPDATE 6 Feb 2016 - Copyright claim on the music so I changed it.

[@tolgaguven3025]

what is the name of the backingtrack

[@TanM]

@@tolgaguven3025 Discard by Jincheng Zhang

[@StephenTack]

You really make that look easy. Nice music too.

[@Donatillo1961]

I watch this many times...relaxing to see him build !!!

[@abelemiliano4067]

instaBlaster...

[@robertz5958]

Awesome thanks Andrew you make it look easy! I have been to Bunnings and checked out the XPS foam and now I am going to make the cutter! Thanks for the inspiration but even more for the proof that everyone should have a go at new things. You can do it!!! Cheers Robert

[@AndrewNewton]

Excellent. It is very satisfying, and not too expensive when you stuff it up

[@grahamrdyer6322]

You make it look so easy...That's skill.

[@virriki627]

How ingenious and simple, bravo!

[@fernandofernando7710]

Maybe 30 years ago a couple of friends and me use to made our surfing boards using exactly this technique. After that we paint them, then fiber, applied epoxy resin... and they were really good ones. Now we are all 50+y.o. And no more fun with it, I miss it...

[@AndrewNewton]

Same here, I made a sailboard in the same way. Still have it!

[@brl_channel3109]

the results are amazingly good, plus great music too

[@DonDegidio]

Andrew, Sure make that look easy. I noticed you changed your procedure from the June video by cutting the top airfoil, then flipping it over to do the bottom.

[@AndrewNewton]

+Donald D'Egidio Well spotted. I prefer this method now.

[@boonie8548]

Hi Andrew, I've been follow your channel over 2 years now, you are great engineer and brilliant pilot. Complete package, fair dinkum :-)

[@AndrewNewton]

Thanks Boonie. Very kind of you.

[@big5astra]

Very nice and clear video, well covered in the camera angles too. Good job!

[@AndrewNewton]

+big5astra Good to hear, thanks.

[@Jartisann]

slow and meditative = great result.

[@Lagggerengineering]

I absolutely agree, this video is phenomenal!

[@Top-Jimmy]

WOW! - Have always wondered how to do this at home. Great video!

[@AndrewNewton]

Easy, give it a go.

[@whataboutbob7967]

A friend of mine has a hot wire table, they make all kinds of things. No airplane wings tho. Those wings are very nice, and should work well.

[@fatenhappy1]

Love the simplicity of the way you get the message across ..."I love airfoils. Just love the smooth curves that produce magical lift..." This is your quote not mine from your previous video !!! And I couldn't agree more. I have been tied up within the aircraft industry nearly all my working life.... I'm now an old grotchety at 64 ... and yes it still fascinates me. I've been fortunate enough especially in the last 20 years or so to even teach on that very subject often in all manner of exotic locations all around the world .. LIFT vs WEIGHT and THRUST vs DRAG and yep still gets me in ... all just differential air pressure over the wings chord ... :-) so just explain to me again how does that 400 tone aircraft get up in the air ... amazing!, love it!

[@AndrewNewton]

Great comment thanks. Wish I knew more about the theory of flight but it gets very complicated quickly.

[@davidr5343]

Love what you are doing Andrew!

[@DougMacGregor]

Brilliant Andrew sir!

[@VK5ZSH]

very well done, you made it look so easy.

[@Droneboy-72]

Sweet I cut a pair years ago worked a treat

[@RT-eb6vo]

Awesome, thanks for sharing.

[@1955chriss]

Merry Christmas to 1 and all

[@bradgray8064]

Excellent. I just have to try it. I've got the foam and the plans and the nychrome wire.

[@AndrewNewton]

It does take some practice, have to move smoothly.

[@salafkadhar4251]

Andrew good job. very nice.

[@ricknoah9184]

Please show how you'd do a tapered wing where you have both a reduction in chord and relative chord height. My concern is that the wire will be moving slower at the tip end and faster at the root. Won't the slowness of the tip end wire cause the foam to overly melt while the speed through the root end is just right ?? Guess a LOT of trial and error will be involved. LOL. But I think it's doable.

[@AndrewNewton]

Yes you're right. Usually requires more sanding to smooth out ripples on the narrow end.

[@campbellshaw8698]

Good clear video- you make it look easy. Inspires me to give it a go..

[@AndrewNewton]

+Campbell Shaw It is easy once you find the right wire/voltage combo.

[@marshal7102]

You have this down to an art I've just cut out my first wing panels with my home made bow using 28mm galvanized steel wire and a automotive battery charger. I am waiting on my nichrome wire to come in from ebay for better results in heating and tension control. I have found that only certain wire can be used and it is must be resistance wire and it will be fine.

[@AndrewNewton]

Yes the wire I use is about 5 Ohms per metre

[@seanmaguire2010]

wow and not single strand ill have to chk that out

[@andyshort3300]

Very inspiring video you make it look so easy.

[@AndrewNewton]

+Andy Short There are a few tricks but it is quite easy.

[@amacfpv]

I wish this video was longer, I only got half way through my beer ;)

[@nigelnightmare4160]

Slow down Bro, You drinking way too fast!;-)

[@sunnykeerithodu6660]

Great work.....

[@TegoSuwarto]

Good job

[@colinsteam]

Excellent, just excellent.

[@AndrewNewton]

Thanks

[@yellowbusguy]

I worked in the foam industry and we did quite a bit of hot wire cutting. Be sure and ventilate those fumes away from you. This produces some nasty stuff you don't want to breathe. Those wing panels are beautiful.

[@AndrewNewton]

+yellowbusguy Thanks for the warning, the dust from sanding is bad too.

[@think2cre81]

That was so satisfying 😌 aaaahhhh ... I'll take 2 please lol 😆

[@guytero8812]

Woweeeee! 👍🏼 👌🏻 Perfect! I'm sure that Andrew has a wonderful wife who puts up with hobby like my wife. 😂😂😂

[@AndrewNewton]

You got that right!

[@snells-window]

Great technique!

[@Jimgoodwin846]

Well I did it! I purchased the components for my very own foam cutter.

[@AndrewNewton]

Excellent Jim. Dont expect good results straight away, it does require some practice.

[@dougkuechenmeister8733]

Very nice, Thank you!

[@rcplanes3131]

Nice technical ! Great work

[@harindrawisnu]

your videos are relaxing as always...

[@greggeshelman]

Don't have to do straight wings. Don't have to have the same airfoil shape at both ends. With different templates and/or sizes at each end the shape will smoothly transition from one to the other. Can even put a bit of twist in the wing. The Wright brothers twisted the tips of their Flyer wings slightly downward to give them better stall performance. When the middle stalled the ends weren't yet in stall.

[@MsMizlicious]

watching this is oddly satisfying

[@AndrewNewton]

You're right, the whole process is very satisfying

[@BuceGar]

Very cool.

[@robertshaver4432]

Very nice, I use Masonite board for templates, I'll have to try your alum. flashing :)

[@AndrewNewton]

+Robert Shaver Much easier to cut out but the thin end can be a bit bendy. I'll try some sort of reinforcement or doubling up the trailing edge on my next template.

[@cicco1838]

great work as Always thank's..

[@rainermeister1504]

Geniale mensch .💎👍

[@zoxwolf2133]

Beautiful work mate :)

[@EnglishTurbines]

Nice Video Andrew, it really is as easy as you made it look when you have the correct wire tension and temperature....I have a set of my own, just debating how to finish them...I'm leaning towards balsa LE and TE and Solarfilm for lightness....:)

[@AndrewNewton]

+EnglishTurbines Ooh Proper job. Yes there are a few tricks of the trade.

[@EnglishTurbines]

Andrew Newton Thought about just covering in paper too...It might make a good follow on Video if a good cheap way could be found, although film from HK is still reasonably cheap...

[@stephengloor8451]

Now all you have to do is start vac bagging the wings and you will have fully composite models coming off the production line ....

[@AndrewNewton]

+Stephen Gloor Hmmmm, one day maybe

[@oasianturi]

hi great job. how many milli millimeters of nickel wire did you use and what is the voltage. what kind of foam do you use?

[@rva1945]

How do you manage to align both foil templates? BTW nice job!

[@AndrewNewton]

Thanks. Measured up from the flat bottom of the foam to marks on the template

[@fsxpilot8355]

Great stuff, got a lot of info from your video's and going into serious efforts myself. For my first project (which pushed me to hotwire technique fast ) I wanted to combine a scratch built delta wing with the fuselage of a Lidl XL glider. i got some good templates but i was wondering if the foam could be cut evenly and not heat up to much at the tip? Caus the travel is a lot larger on the inner side of the wing then the outer so i wonder if the foam would hold up the longer wire cutting time on the tip in comparison to the normal wire cutting time at the base rib . I hope it makes sence what i am trying to say ;)

[@AndrewNewton]

It's always a problem with tapered wings. No way around it really.

[@Thalarctos.]

💖

[@Floatflyer1]

With a flat bottomed airfoil, why don't you just match the flat bottom to the bottom of the foam and avoid having to cut the bottom? I am envious of your smooth cutting, mine seem to always have grooves in the foam, sadly. Wonderful video, thank you.

[@AndrewNewton]

The airfoills I am using are not totally flat bottomed, even the Clark Y has a curved lead in to the under half of the leading edge. I would have to sand that by hand if I didn't cut the whole thing.

[@Floatflyer1]

@@AndrewNewton Another question has come up. I am trying to cut wings with a flat bottom and line up the bottom with the bottom of a 2" thick piece of pink foam hoping to only cut the top airfoil shape. All goes well BUT when I remove the newly cut wing it is warped from the root to the tip!!!! I left over foam remains straight! Would this be cured by placing templates in the middle of the foam and cutting both top and bottom or what is going on???

[@editglobalgaming8192]

Very nice and fantastic I wish it was me be friends please

[@DutchRC]

Nice demonstration Andrew :) Those foil-templates are made out of lead / alluminum?? I've tried wooden ones in the past, but it's hard to get them smooth enough..

[@AndrewNewton]

+DutchRC ADVENTURES Aluminium window flashing, easy to cut with scissors.

[@DutchRC]

+Andrew Newton Thanks :) Looks to be working flawlessly :)

[@kikoway1]

+Andrew Newton great job as always. Foil templates alluminium, is 0,5 mm?

[@cyberschn1tzel997]

+Andrew Newton wow never had this idea... I think i even use this on my wooden templates on the edges. I gotta try try this :)

[@AndrewNewton]

+enrico p It's 0.3mm Aluminium window flashing

[@f76gg]

good job!

[@AndrewNewton]

+Felipe Garcia Thanks Felipe

[@SanthoshKumar-mr5ss]

Hi.. Did you used polyurethane foam for making wings?

[@AndrewNewton]

It's called Knauf XPS foam

[@allentobolewski7273]

What is the power supply? I'm using a 12 volt battery and .025 nichrome, but it goes part way and stops

[@AndrewNewton]

4S Lipo 16V, or Variable power supply set to deliver 5A

[@АндрійЯковлев-м6и]

@@AndrewNewton And what about nichrome wire thickness? I use 0.3 mm but it so think

[@stealhty1]

Wrap it with fiber glass and you have made your rotorcraft wings

[@elcotorro]

GREAT WORK ¡¡

[@ashok305]

Music is....Discard by Jincheng Zhang

[@billjonesnation]

I bought a model train control for my power supply about 15 years off ebay. I found the thing in a box and I think now is the time to finish the project! Thanks for the video. Do you find the leader wire better than nichrome? I am finding nichrome hard to come back and fishing gear seems easier to source. I hear the fishing leader won't change size much as well with the heat.

[@AndrewNewton]

I haven't tried Nichrome yet. The SS fishing leader works well for me. I did keep breaking lighter weight wire in the past.

[@jerrywhidby5259]

How exactly are you precisely aligning the two pieces of window flashing? I see that the front of the foil is butted up to the edge. Did you just place something under both pieces, before pinning them, to get an equal distance from the bottom? It looks to be at a bit of a tilt, so I was not sure.

[@AndrewNewton]

+Jerry Whidby Just eyeballed it Jerry, probably not totally accurate but close enough. Would be better to mark a line about 4mm up from the bottom and a point on the front edge to help alignment.

[@soumitrajewalikar8865]

Can we cut balsa wood by this method?

[@AndrewNewton]

Not hot enough I think

[@barneybetelgeuse6273]

Nice job do you put spars in the wings also how do you regulate the heat in the wire

[@AndrewNewton]

Variable voltage power supply or choose 3S or 4S battery depending on the wire length. I glue edge-on 6mm or 3mm CF strips in for spars. Just cut a slot top and bottom. Much more info in the Hotwire Playlist

[@isquerdo1]

Hi! top! Show! I'm from Brazil.

[@AndrewNewton]

+Gilmar Isquerdo Greetings to Brasil

[@alfaspiderveloce6617]

Hi-- great video--- What is the longest wing that could be done by this process? With increased volt/current, could you cut a 12 ft foamy wing?

[@AndrewNewton]

Should be possible as long as you can make a frame strong enough to hold the tension. Might be problems with drag on the wire in the middle. Much easier to cut in sections and join together.

[@alfaspiderveloce6617]

@@AndrewNewton-- Wanted to laminate 8 ft panels of foam in staggered pattern to keep 12- 14 ft wing as rigid as possible. Then cut the entire wing in one piece. Have not seen anyone tension a wire that long. Have heard of fishing leader that may work as resistance wire, just asking if you had heard of anyone cutting a wing that long. Thanks,

[@AndrewNewton]

@@alfaspiderveloce6617 No I have not heard of cutting wings that big. I use fishing leader wire. 40kg single strand.

[@mickcarson8504]

Hello Andrew. I used to do same thing but on a long foam block. Is that balsa wood?

[@AndrewNewton]

XPS foam

Hello Andre, how are you? what material is this you are cutting?

[@AndrewNewton]

Doing well. Linked in the description

[@YasinHamzelo]

شما از چه نوع چوبی استفاده کردید

[@AndrewNewton]

Pine for the hot wire cutter frame

[@spencerboaz2385]

What type of foam are you using and where can you get it . That looks much better than the folded foam board tape raped wings . I have multi-copters and left over motors out runners and esc's a 6 channel flysky radio I need servos . Hot wire looks much better to me . Are you using carbon fiber arrows for spars ? I'm looking for longer range for Video and fpv .

[@AndrewNewton]

+Spencer Boaz All the materials links are in the video description. 7.6mm CF arrows or 6 x 1mm or 3 x 0.5mm for spars.

[@spencerboaz2385]

Andrew Newton Ok I plan to watch them all again and this time I'll read the descriptions thanks .

[@СергейЛарионов-у8в]

What is the optimal wire temperature for cutting?

[@AndrewNewton]

Don't know the actual temperature. Just have to do test cuts and adjust the current / voltage. Glowing red is too hot

[@СергейЛарионов-у8в]

@@AndrewNewton Thank you!

[@clivemilner8261]

Andrew, thanks for the Post. I want to use a digital wood burner may be guitar wire st .6 Ohms. I can vary heat output. If I do not use nicride wire Will I have problems?

[@AndrewNewton]

No problem, are you going to try it?

[@easy_3d]

Andrew looks similar to the guy from top gear

[@AndrewNewton]

James May or The Stig?

[@easy_3d]

@@AndrewNewton jeremy clarkson

[@faisalshaikh6450]

What’s your wing material that cutting ??

[@SsoulBlade]

How do you sync the 2 sides? (so that the wire is always at same location on both sides) Eyeballing? What about tapered wings?

[@AndrewNewton]

+SsoulBlade Just eyeballing for straight wings. Haven't tried a tapered wing yet but will mark quarter, half and three quarter points on each end and try to pass them at the same time

[@bitsbytes123]

@@AndrewNewton I will use this on my flying wing project. the taper ratio is about 2.08

[@espr7564]

Beats me Andrew? how do you make sure both templates are exactly lined up at each end??

[@AndrewNewton]

I just eyeball it, same distance back from the front and bottom edges of the foam block.

[@rcthailandbasic9734]

🤟🤟👍🙏

[@rabaranwer9752]

hello my master..i hav one qes..what software u use for editing vedio pls?thanks

[@AndrewNewton]

+Rabar Anwer Grasshopper, I use iMovie on a mac

[@Civilsitis]

Human CNC !!!

[@waleswideman1]

How light is that wing compared to a armin foam bird wing?

[@AndrewNewton]

Same weight as my depron Armin wings

[@ChrisMisMYhandle]

hi Andrew. what do you use as a power supply for hot wire cutting?

[@AndrewNewton]

Either an adjustable power supply or 3S or 4S lipo depending on the wire length.

[@GM_GetMotive]

Which material you are cutting , can i cut wood with this hot wire

[@AndrewNewton]

Which material is in the description. I doubt it would cut wood.

[@adnaneadnane593]

Bro how you cut the aluminum for the airfoil plz tell me

[@AndrewNewton]

Strong scissors

[@adnaneadnane593]

@@AndrewNewton i mean the shape of the airfoil,

[@parjacpar3077]

Thanks for posting this as got balsa wing to replace and thaks to your video might do it your way but what foam did you use ?

[@AndrewNewton]

XPS foam, link in the description

[@parjacpar3077]

Thanks for letting me know

[@stephenclarkMr]

Is there much of an advantage moving to a 4s lipo over the 3s you used in the previous video?

[@AndrewNewton]

+stephen clark Oh yes, big advantage. Especially for the 750mm wing halves. Hotter wire = Faster cutting speed = smoother cut. 3S was OK but slow, 6S (2 x 3S) was too hot and burned out the wire. 4S is perfect.

[@youmanskids]

+Andrew Newton nice job, you make it look easy! I have used a BRUSHED speed controller to adjust the heat to the wire. works great,

[@PrabhavChauhan66]

How to align the templates on both sides properly?

[@AndrewNewton]

Mark the templates centre line and measure up from the flat base of the foam, both ends

[@quintentaeldeman7409]

Where can i find the aerodynamics that litlle paper thing for the wing i want to print it but i dont find a plan for a delta wing

[@AndrewNewton]

You can find it. Just search for airfoils

[@quintentaeldeman7409]

@@AndrewNewton thank you so much I did not know that this was called so that's why I found no plans on the internet

[@OZSCQUADS]

Hi Andrew, Can I ask you a question. I am buying a 3in1 Soldering/Rework station which has variable DC output. There appears to be several versions though, 1amp, 2amp, 3amp, etc. For hotwire cutting, 1A would be sufficient, right?

[@AndrewNewton]

Not enough for my wire, I'm using 4A

[@OZSCQUADS]

Andrew Newton wow. Ok. Maybe I should consider a different source.

[@OZSCQUADS]

4A.. I was planning on just using guitar wire..that should be OK right. I could use an old computer power supply I have. some good amps there.. lol

[@AndrewNewton]

Yes the thinnest string is the one to use I believe. There are plenty of tutorials on adapting a PC power supply, but I managed to trip the house safety switch when I tried. So I now have a proper adjustable unit.3S and 4S Lipo batteries work fine too.

[@t6texanaus]

The weights you use, how heavy are they?

[@AndrewNewton]

1kg and 4kg scuba weights

[@t6texanaus]

@@AndrewNewton cool thanks

[@caovondantocdao9611]

anh dùng vật liệu gì vậy?

[@AndrewNewton]

In the description

[@lightpolebluelamaa4207]

How to you get the templates to line up

[@AndrewNewton]

Measure up from the foam board flat bottom to marks on the leading and trailing edges of the templates

[@attic6]

Awesome, what thickness wire are you cutting with?

[@AndrewNewton]

+Jimmy Reynolds Details in the description Jimmy

[@attic6]

+Andrew Newton Thanks, i was looking at the list. my bad.

[@christophertadeo6120]

Hey you can use hot wire for yachts too, correct? 😳

[@AndrewNewton]

Which part?

[@christophertadeo6120]

@@AndrewNewton masts?

[@AndrewNewton]

Yes, but the foam would need lots of reinforcement

[@Top-Jimmy]

@@christophertadeo6120 A mast? You mean a hull surely

[@christophertadeo6120]

@@Top-Jimmy no.

[@crankstermedia]

Hi Andrew, thanks for a great video and the aussie links too :) Your link to your video about your hotwire setup is broken. Is that video still available ?

[@AndrewNewton]

+Aus Crankster Oh thanks, link is fixed now.

[@crankstermedia]

+Andrew Newton Brilliant Andrew, thanks. I was going to start scratch building here in Melbourne using foam board but it is more hassle than I realised here. I like your wing method and will give it a go. Maybe I'll need to use the foam board for the fuselage. What do you use? Darren

[@AndrewNewton]

+Aus Crankster 6mm depron from tradewarehouse. Link is in the notes. I used to fold wings from depron but I find hotwire to be easier and cheaper

[@crankstermedia]

I know that foam :) I was looking at the other day at Bunnings wondering how I could use it. Now I know ! Gotta give this a go. Thanks again.

[@vamsi1997]

Which material is your cutting

[@AndrewNewton]

Link in the description

[@theillitistpro]

That's what I'm missing when I do this... Two keys of Coke.

[@AndrewNewton]

Would speed the process up!

[@theillitistpro]

@@AndrewNewton Or would it??? LOL

[@DadsRCHangar]

Very cool, what plane are they for?

[@AndrewNewton]

Fokker Dr1

[@DadsRCHangar]

Andrew Newton oh wow, that be interesting to see you make the whole thing 👍🏻

[@AndrewNewton]

@@DadsRCHangar kzbin.infosearch?query=Fokker

[@DadsRCHangar]

Andrew Newton oh it was 4 years ago. Silly me. 👍🏻

[@faisalshaikh6450]

What’s its density? if you know

[@AndrewNewton]

Link in the description

[@scottnathan2912]

Where do you get all the stuff from, to do this?

[@AndrewNewton]

Did I forget the links?

[@scottnathan2912]

@@AndrewNewton I might be seeing it now.

[@AndrewNewton]

A miracle!