Down To The Wire
Why this project?
Recently, I have been getting into building terrain models for tabletop RPG games and this involves a lot of cutting foam. I wanted to streamline cutting out foam pieces and after doing some research, a hotwire cutter seemed to be the perfect solution. This would allow me to create laser-cut guides which could then be used to cut multiples of the same shape from foam using the hotwire and allow for more precise angles and levels of detail.
Recently, I have been getting into building terrain models for tabletop RPG games and this involves a lot of cutting foam. I wanted to streamline cutting out foam pieces and after doing some research, a hotwire cutter seemed to be the perfect solution. This would allow me to create laser-cut guides which could then be used to cut multiples of the same shape from foam using the hotwire and allow for more precise angles and levels of detail.
How it works
The device uses and AC/DC power converter that outputs 12v. This is then connected to a 10k potentiometer that can adjust the output voltage from 0v-12v before the current is sent through a 25 gauge nichrome wire which will heat up to cut the foam. This wire is suspended between the base and an arm that extends from the back of the base over the center. A switch was also added to the design so it can be turned on and off without needing to be unplugged.
The device uses and AC/DC power converter that outputs 12v. This is then connected to a 10k potentiometer that can adjust the output voltage from 0v-12v before the current is sent through a 25 gauge nichrome wire which will heat up to cut the foam. This wire is suspended between the base and an arm that extends from the back of the base over the center. A switch was also added to the design so it can be turned on and off without needing to be unplugged.
Why was this meaningful?
This project was significant to me as it tackled a pressing issue in my terrain modeling hobby for tabletop RPG games—inefficient and imprecise foam cutting. By devising a hotwire cutter, I aimed to streamline the process, ensuring greater accuracy and saving valuable time. Through research and application of electronics and crafting skills, I developed a device featuring an adjustable voltage control and an on/off switch for versatility and ease of use. This endeavor not only improved the quality of my terrain models but also expanded my knowledge and passion for innovation, embodying my commitment to practical solutions and enhancing my crafting experience as a whole.
This project was significant to me as it tackled a pressing issue in my terrain modeling hobby for tabletop RPG games—inefficient and imprecise foam cutting. By devising a hotwire cutter, I aimed to streamline the process, ensuring greater accuracy and saving valuable time. Through research and application of electronics and crafting skills, I developed a device featuring an adjustable voltage control and an on/off switch for versatility and ease of use. This endeavor not only improved the quality of my terrain models but also expanded my knowledge and passion for innovation, embodying my commitment to practical solutions and enhancing my crafting experience as a whole.
The process
I began by designing the case using Makercase and saving it as a .dxf file. I then laser-cut this and set the pieces aside. I then tested the circuit to make sure the voltage regulator would work properly and that the schematic I created would function correctly. After I confirmed that it worked, I began placing the components into the base while drilling out three holes for the switch, knob, and power cable which a filed down to the needed shapes. After this, I designed the pieces for the arm in Fusion360 and laser-cut them before attaching them to the top of the box. I then ran the nichrome wire through a hole drilled in the base and used a bolt and wingnut on each end to secure the nichrome wire to the the VCC and GND wires. I finished by closing up the box and the final product was finished.
I began by designing the case using Makercase and saving it as a .dxf file. I then laser-cut this and set the pieces aside. I then tested the circuit to make sure the voltage regulator would work properly and that the schematic I created would function correctly. After I confirmed that it worked, I began placing the components into the base while drilling out three holes for the switch, knob, and power cable which a filed down to the needed shapes. After this, I designed the pieces for the arm in Fusion360 and laser-cut them before attaching them to the top of the box. I then ran the nichrome wire through a hole drilled in the base and used a bolt and wingnut on each end to secure the nichrome wire to the the VCC and GND wires. I finished by closing up the box and the final product was finished.
Final shots
Below are a few more shots of the final project in good lighting
Below are a few more shots of the final project in good lighting
