This is a model of a table top foam cutter, printed in 4 parts. The base is 100x100x30mm and the available height of cutting wire is 90mm.
A NiChrome wire or guitar string and a DC power supply is required. I have found that the best electrical parameters are 1-1.5V and 1.2-2A depending on the temperature required. It is also possible to cut thin plastic parts such as PLA or HIPS sheet, as well as paper.
The back plate attaches with four 4mm self-tapping screws and a 7mm diameter compression spring is used to ensure the wire stays taught. I suggest a spring rate of 2N/mm or greater.
A 6mm diameter 25mm long bar fits in the slot on the underside for wrapping the wire around. Channels have been made around the outside edge of the arm and under the base for routing power cables.
Corner rounds and fillets have been applied to prevent issues with slight print overrun on interference fit components. Please take a moment to look over the finer features of the model to ensure they will print well with your machine.
STEP files provided for editing and other formats may be available on request.
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All parts can be printed without supports apart from the arm. For this I used the 'support everywhere' option in Cura.
Base is best printed with the top face against the build plate.
Printed at 50mm/s and 20% infill, the base takes approximately 3 hrs 30 mins. The remaining parts take 1 hr total at 100% infill.
The STL files provided use dimension tolerances that work well with my printer, a DreamMaker Overlord (delta style). STEP files have been provided for you to tweak as required.
I would suggest printing the base first and then tweaking the other part dimensions to fit.
As a rule of thumb: Internal diameters have been increased by 0.5mm.