TELEGONUS: 4 AXIS CNC HOT WIRE CUTTER
Built a functioning 4-axis CNC hot wire cutter that cut blocks of polystyrene foam into desired 3D shapes based on G-code input.
In fall 2018, for my final project for Principles of Engineering, I collaborated with four other classmates to build functioning 4-axis CNC hot wire cutter that cut blocks of polystyrene foam into desired 3D shapes based on G-code input. Our mission was to create an easier way of cutting complex shapes out of foam. We were inspired by one of our member’s struggles to cut airfoils on their model plane project team as well as other tribulations with the current hot wire cutter in design class studios. Because foam is a cheap material, we wanted to give people the capability to create large shapes of intricate geometry that would otherwise take a lot of time, money, and experience to mill, 3D print, or machine in a different manner.
I was responsible for designing a vise that secured the foam piece onto the plate while the piece is revolving and being cut by the hot wire. The vise is driven by the stepper motor and controlled by Arduino Mega.
System Overview
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Vise
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The vise secures the foam piece onto the plate while the piece is revolving and being cut by the hot wire. In order to ensure that the vise doesn’t shake while rotating, we fabricated a bearing block from aluminum stock so that the plate axle would go through. The block had a bearing race track where the bearing balls can sit. The plate support sits on top of the bearing balls and the balls prevent the plate support from wobbling. On the center of the plate there are two wooden spikes that the Styrofoam block can penetrate. Users can easily position the Styrofoam block onto the plate without worrying about the block shaking.
The skewers not only held the foam well but also were easily repairable in case they broke off. The plate had enough surface area for the foam block to sit on.
Bearing block that secures rotation
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