Hot Foam cutter for RC aircraft

**rckeith** · 18-01-2013

Hi Guys

Few more updates. I've added home/limit switches and run some test cuts. Its starting to become a bit easier now. Here's a link on my website CNC Config Mach3 and TB6560 with some sample cuts and setup.
I've documented the configuration so anyone else using the same set up can save a bit of time and head scratching.
The biggest learning curve I think is getting all the software to work, but I use Mach3 and profili2 which do good job. I'm also looking at InkScape as there is a gcode extension for it. Might use this to cut fuselages.

Keith

**rckeith** · 30-06-2013

This video show the flying wing I made with the cnc foma cutter its on my video page RC Video's - rcKeith | Projects

It was a quick test to see how it could cut wings and what a fantastic flyer its is. Its my favorite flyer now. Goes like stink and can fly at snails pace as well.
Have now purchase DevFus software to make fuselages which I going to test on a 50 inch wing span Hurricane.

Keith

**rckeith** · 10-08-2015

I've added a lot of details to my build including plans, instructions and parts/cutting lists all at my website www.rckeith.co.uk . I've have a video almost ready that should be up in a few days on using Profili Pro 2 for cutting foam wings which I'll then follow up with one on Dev Fus Foam. I've used these to produce a 50 inch Wing span Hawker Hurricane. A few images below. Not finished yet because of other stuff getting in the way. I'm now looking to build a CNC router probably a Openbuilds OX but also may try and build Mark Carew's Phlatprinter this seem ideal for producing foam models. I like the fact its fairly compact and can produce large parts.

**rckeith** · 13-08-2010

Hi GeorgeD

Yes the width can be adjusted to suit. The only thing between the towers is the hot wire,

Keith

**GeorgeD** · 13-08-2010

How do Keith.

You do well to put the towers on a sliding base for differing widths apart.

ie use some T channel aluminium rack and rebate the T track in 25mm baseboard and then space the towers when ever you feel the need to widen them?or just have them permanently affixed to a base board because there's no stability in that design ie a gust of wind will blow em over :heehee: and thats not good for the motors//mechanics if you want to avoid damage.

**rckeith** · 13-08-2010

Hi George

The towers will be clamped/screwed down on a base. The tension on the hot wire would certainly pull them over. The main reason I chose this design is that I have quite a small workshop so when not in use I can store them away. Once I've built this one I'd like to do a cnc router but I'll really need to work that one out, with the space I have. Problem I have is that a lot of space is taken up by 10 radio controlled planes of different sizes and I have 2 kits that I haven't even started yet.

Keith

**GeorgeD** · 13-08-2010

Not to big...hmmm! how about this size? fits neatley on the workbench and has a static z axis,could easily be made to the size of your requirements.

http://www.cooperman.talktalk.net/tweakie2.jpg

http://www.cooperman.talktalk.net/

**rckeith** · 13-08-2010

Hi George

Phew! what a website. Very impressive certainly an inspiration to us all. I'll have a good read of it later certainly some real good information. Have you any recommnedations for lead screws at a reasonable cost. I've seen foam cutters done with threaded rod but most peope seem to recommended a ACME screw thread.

Keith

**GeorgeD** · 13-08-2010

I'm making my own lead screws from Derlin.

I could make you some at a reasonable price,send me a PM if interested?

For your foam cutter,M12 threaded rod will suffice.

oops! make that....

Making my own ball nuts from Derlin. lol