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Foam Sheet Cutting Method
by David Fordham

I have the wire a little more slack than I would if I were cutting something like wing cores. This causes the wire to bend away from the advancing foam and builds up tension in the wire which actually helps achieve a smoother cut. The tension helps by pulling the wire through the foam if and when I pause while pushing. I use this bend in the wire to also judge my cutting speed. If I slow down the wire straightens out. If I push to fast the wire starts to bend more. If the bend stays consistent then so is my speed.

Custom Made Unit
Manufacturer of the Transformer - Staco
.015" Nichrome Wire
Here is a stack of foam I cut over the
course of an evening.

The sheets are 8x36" and the thicknesses range from 1/8" to 1-1/4"








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