Mostly 3D Printed CNC Foam cutter

For over a few months now I have been building a hot wire foam cutter. First I was just trying to make a hot wire bow for cutting foam
and making an air foil for my R/C plane with 3D printed templates and metal foil tape. It sort of worked. But I could never get a 
good cut without having to do a lot of sanding and even then it didn't look good. Next I tried to make a gravity actuated foam
cutter like the old Tekoa feather cut foam cutter. It worked better but I kept having problems with the hot wire snagging in unpredictable
ways and not getting a good cut. My next thought was to just build a cnc version that I have seen on YouTube by RCKieth. Lots
of good information on his channel and site by the way. I came across a Thingiverse version that used 3D printed brackets and linear
rails.
www.thingiverse.com/thing:3676825/files

For the control system I am currently using GRBL 5X with the RAMPS 1.4 board. That Said I will be switching to LinuxCNC at some point.
Mostly because I intend to use the same machine to do hot wire and hot pin style foam cutting. I am posting some pictures in later posts
.
 

   

 
 

the cutting bow
 
 
 
 
 

so basic travels are
450mm or  17.7in. in X travel
350mm or 13.78in. in Z travel
and when equipped
700mm or 27.56in. in Y travel

Though the photos don't show the machine in full setup configuration
it will be 1000mm wide X 600mm long x around 500mm tall.

current control is for now GRBL 5X
and RAMPS 1.4 break out board

The bow uses a 48in. long  1in. X 1in. X 0.0625 wall aluminum boom
I 3D printed the Isolator adapters out of PETG and used 2 
carbon fiber arrow shafts cut in half for the tensioner posts.
I retained the threaded ends for the wire attachment and electrical
connections. I use a 22ga. nichrome wire for the hot wire.
For power supply I use a 450 watt 24 volt std power supply
and I use a 30 amp PWM brushed motor speed controller
to dial in the energy needed for the wire. That also means
I can use thinner nichrome wire if I so choose.

many changes coming soon

 

I actually will be using it in 4 axis configuration. Though my Slow ultra stick will be using straight wing cuts.
That's why I am using a bow to handle the wire tension. The attached picture shows the wire yoke. It's designed
to keep the wire mostly in place but will allow it to slide between the two metal washers and also deal with the angular
alignment when the two Z axis are not parallel to each other . the bearings will also allow
for angular misalignment of the two X axis. As I am typing this I am starting to realize that I may need to do a video
showing the misalignment capabilities of how the system works. Fortunately I have time this weekend to do it.
 

Those are some really nice machines you have built their.
I am going have to be careful it looks like it becomes an addiction. LOL