This cutter heats a 16 gauge nichrome wire hot enough to glide through the densest foam. It doesn’t seem to be effective at cutting anything else. Not even paper. Nichrome is the same wire used in electric baseboard heaters, toaster ovens, blow dryers etc. Its only purpose is to get very hot when the correct wattage is put to it. This wire is readily available online. It is my understanding that all nichrome will eventually pop after a certain amount of use, so I went with a lower gauge for longer life. Nichrome Popping Experiments
The design is super simple. All you need to do is set up a transformer that will put enough wattage through the wire to get it red hot. It is important that the wire is attached to a spring on one end. The wire relaxes and becomes less taught as it gets hot. The spring is necessary for keeping the wire taught as you cut.
BILL OF MATERIALS |
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3/4″-2’x3′ Particle Board |
Aluminum Angles |
24V 43W Transformer |
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18″L-2″x4″ |
(4) 3″Lx1/4″D Bolt & nut |
16g Nichrome Wire |
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Several 2″x2″s |
Spring |
Switch rated for mains power |
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1/2″ scrap plywood |
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(2) Alligator Clips |