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2008Cases/Carts/Stands and Transport forum

Building a hot-wire foam cutter for custom case padding

18 years old. Gear and prices may have changed since.

What the thread found

  • A hot-wire foam cutter can be built from basic materials including particle board, lumber, florist wire or nichrome wire, and a power source for under fifty dollars.
  • The cutting process involves tracing the item onto cardstock, creating a template, tacking it to the foam, making a pilot hole with a box cutter, threading the hot wire through, and slowly moving the wire around the template like a jigsaw.
  • Nichrome wire works better than steel florist wire for hot-wire cutting.
  • A household light-dimmer switch paired with a twenty-five volt two-amp transformer can power a hot-wire foam cutter.
  • Pick-and-pluck foam deteriorates over time when used frequently, especially in thin areas and strips, while custom hot-wire cut foam holds up better to long-term use.
  • Spray adhesive can help preserve pick-and-pluck foam temporarily, but it eventually comes unglued with regular use.

Depends on

  • The original post referenced external images that are no longer accessible.
  • One person reported pick-and-pluck foam with spray adhesive lasting about two years before deteriorating under heavy daily use with multiple insertions and removals.
  • The effectiveness of spray adhesive methods was reported anecdotally rather than systematically tested.

Gear in this thread

Voltcatalog

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