HOT WIRE FOAM CUTTER
The intention of this project was to design a product that uses 3D- printed components that would allow its user to shape, join or apply finishing processes to thermoplastic materials. We were given 6 inches of 20 AWG nichrome wire, 12 inches of 20 AWG copper wire, On/off Switch. We designed a hand tool that uses dissipated heat across a nichrome wire that conducts electrical current. The design is safe and controls the flow of electrical current.
Collaborators: Adrian Perez, Jose Tejeira, Ignacio Fimbrez, Mackson Li
Sketches
The small size of our product is the result of the following:
We wanted the device to make precision cuts, so the smaller and more compact the handle tool is, the more accurate and the more control the user has when using the tool.
The switch available for us had to be pressed continuously for current to flow. For this reason we decided that making the device smaller would be convenient because the user’s finger wouldn’t have to travel far.
Initial Sketch
Assembly & Results
Learned that the nichrome couldn’t be soldered to the copper wire. Consequently, we knotted the wires as much as we could to ensure proper connection for current to flow.
Inside the 3D handle, we poured a mix of clay with the intention of protecting the case from being melted due to the heat dissipated from the wires, and also this mixture provided a strong foundation for the nichrome wire be firm and in place.
The curves in the bottom part of the handle were added for aesthetic reasons, giving the tool a pleasant and positive appearance; and also for the fingers to rest and improve grip when using the device.
