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Cutting Foam: The best way to cut polystyrene is with a hot-wire cutter. The heated Nichrome wire cuts through foam like a hot knife through butter! More Tips |
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- Cut out the top and side (profile) views from a copy of your working drawing. Then, carefully outline the views onto the polystyrene blank.
- Use a hot wire foam cutter to roughly shape the blank:
- Turn the blank on its side and cut out the profile view first.
- Fit the waste pieces and working piece together and secure them by wrapping two bands of masking tape around the assembly.
- Set the blank assembly upright and cut out the top view. Note: The hot wire will not cut through the masking tape, so you’ll have to work around the tape. When ready, remove the tape and carefully cut those areas last.
- If you haven’t already done so, remove the masking tape and discard all the waste pieces.
- Smooth the corners of your prototype with a sharp knife, the hot wire cutter, or sandpaper. Note: You may have limited success with sandpaper on polystyrene.
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