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Cutting styrofoam the analog way

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Published on Mar 14, 2012

My father is cutting wing profiles for model aircraft out of styrofoam blocks. He is using a home-made hot wire cutter - for straight cuts gravity alone is sufficient, but for curved cuts a machine is used that evenly pulls the hot wire along a pair of plywood templates. To make a perfect cut two ends of the wire have to finish at the same time even if the two curves have different lengths, so an adjustable mechanism of levers and pulleys is used to set the speed at both ends.

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