A CNC Foam Cutter with Hot Wire is a precision cutting machine that uses a heated resistance wire to cut thermocol (EPS), foam, and polystyrene into complex shapes. Controlled by G-code, the hot wire melts through the foam smoothly, enabling accurate and dust-free cutting for prototyping, architectural models, and signage.

This project is ideal for engineering students, model makers, and fabrication workshops who need custom foam designs with high precision.

Parts Used:

1. Frame Structure – aluminum profile or wooden frame for stability
2. Hot Nichrome Wire – main cutting element
3. Stepper Motors & Drivers – move wire along X and Y axes
4. CNC Controller Board (Arduino + GRBL or similar)
5. Power Supply – separate units for hot wire and motors
6. Temperature Control Circuit – adjusts wire heat
7. Linear Rails & Bearings – for smooth and accurate movement
8. Limit Switches – for safety and travel limits
9. CNC Software (e.g., Mach3, GRBL Controller) – for G-code execution