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OT? Styrofoam cut by hot wire

  • Thread starter Rich Grise, Plainclothes Hippie
  • Start date
R

Rich Grise, Plainclothes Hippie

http://www.neodruid.org/images/CutFoam-640x480.jpg

Whoa, dude! I was interested in the thread about cutting styrofoam with a
hot wire. Well, some months ago I saw a hank of nichrome wire on ebay, for
a couple of bucks, which he said was #36, and just today I mic'd it [yes,
that's proper use of the apostrophe - go look it up! - Rich the Pedagogue]
at about .0047, maybe .0048. The thou on Joe's mic are like an eighth of
an inch apart, so I had to interpolate the tenths.

Anyway, in the ad that I bought it from, it said, "28 ohms per foot." I
ohmed it out, and it was within as close as I could get the probes to a
foot apart. :)

BTW, the reason I bought it is because I was entertaining fantasies of
building a THC evaporator. [still am, actually - Rich the proofreader]

But that's a different story. %-) What prompted this post is that I have a
"7.5VDC, 1A" wall wart that came with some kind of radio that somebody
threw away, a set of Radio Shack clip leads, and this nichrome wire.
"Hmm", I says to meself. Did I say I'm still stoned from that ONE HIT!??)

But I remembered that "cut foam with a hot wire?" thread, and I thought,
what's the worst that could happen? So I took a piece almost a foot long,
clipped the clip leads to the ends - you can barely see the red-booted
clip and red VOM lead, which for the pic have been disconnected. I just
clipped the wall wart to a piece of this nichrome wire, on top of a couple
of pieces of ceramic tile I'd scrounged, and it didn't get red, but it got
uncomfortably warm to the touch, like, if I'd held it tightly between
thumb and finger, it'd have left a mark in a few seconds. I don't know how
to estimate temp, but I'd say more than 120 F, but decidedly less than
450! :) So, anyways, this nichrome wire is lying there dissipating heat,
and I grabbed this styrofoam block, and picked up the wire by the clips,
and, well, I cut the styrofoam. :) It was kind of a weird feeling,
actually - I felt almost no resistance (in the mechanical sense) as if I
were cutting butter, please excuse the trite hackneyed cliche. ;-)

Just for context, in the pic you can still see the nichrome wire, and it
looks like it goes into the right-hnad corner of the small block and out
of the top corner? Well, here's the thing. I was so freaking excited at my
wonderful new discovery that I left the wire lying about where you see it
in the picture, and by the time I got around to unclipping the leads from
the wall wart plug, the wire had already melted itself into the botttom of
the small block.

The cavity that looks like a hole somebody tried to drill, who didn't know
what an ordinary drill bit will do to that type/form of styrofoam, is a
hole somebody (I) tried to drill, not knowing what an ordinary drill bit
will do to that type/form of styrofoam. ;-)

But the way the wire cut through it! I did feel the difference, but that
cut is amazing! I did that by hand! Imagine if I put it in some kind of
fixture!

BWAHAHAHAHAAAA! Styrofoam cut to your spec - $0.12 per square inch of new
surface!! ;-D ;-D ;-D

http://www.neodruid.org/images/CutFoam-640x480.jpg

BTW, if you get another server error, please, please let me know, because
as I've said, I'm inside the firewall, and I have to trust my own
blundering configurations to expose just the right stuff to the outside
world. Damn, I'm still stoned, on that one hit, and it's been a couple
hours! I might have another little hit soon though, since it _has_ been a
couple hours. %-}

Oh, yeah, before I hit "send" if you're wondering where that particular
particularly nice block of styrofoam came from, it was in a box that
somebody had shipped some big light bulbs that they've installed in the
shop. Like the size of a 1,000 watt bulb, but halogen or mercury or
something - anyway these big bulbs were packaged in these cool blocks of
foam. :) (inside corrugated cardboard boxes, of course.)

Cheers!
Rich
 
J

Jim Thompson

http://www.neodruid.org/images/CutFoam-640x480.jpg

Whoa, dude! I was interested in the thread about cutting styrofoam with a
hot wire. Well, some months ago I saw a hank of nichrome wire on ebay, for
a couple of bucks, which he said was #36, and just today I mic'd it [yes,
that's proper use of the apostrophe - go look it up! - Rich the Pedagogue]
at about .0047, maybe .0048. The thou on Joe's mic are like an eighth of
an inch apart, so I had to interpolate the tenths.

Anyway, in the ad that I bought it from, it said, "28 ohms per foot." I
ohmed it out, and it was within as close as I could get the probes to a
foot apart. :)

BTW, the reason I bought it is because I was entertaining fantasies of
building a THC evaporator. [still am, actually - Rich the proofreader]

But that's a different story. %-) What prompted this post is that I have a
"7.5VDC, 1A" wall wart that came with some kind of radio that somebody
threw away, a set of Radio Shack clip leads, and this nichrome wire.
"Hmm", I says to meself. Did I say I'm still stoned from that ONE HIT!??)

But I remembered that "cut foam with a hot wire?" thread, and I thought,
what's the worst that could happen? So I took a piece almost a foot long,
clipped the clip leads to the ends - you can barely see the red-booted
clip and red VOM lead, which for the pic have been disconnected. I just
clipped the wall wart to a piece of this nichrome wire, on top of a couple
of pieces of ceramic tile I'd scrounged, and it didn't get red, but it got
uncomfortably warm to the touch, like, if I'd held it tightly between
thumb and finger, it'd have left a mark in a few seconds. I don't know how
to estimate temp, but I'd say more than 120 F, but decidedly less than
450! :) So, anyways, this nichrome wire is lying there dissipating heat,
and I grabbed this styrofoam block, and picked up the wire by the clips,
and, well, I cut the styrofoam. :) It was kind of a weird feeling,
actually - I felt almost no resistance (in the mechanical sense) as if I
were cutting butter, please excuse the trite hackneyed cliche. ;-)

Just for context, in the pic you can still see the nichrome wire, and it
looks like it goes into the right-hnad corner of the small block and out
of the top corner? Well, here's the thing. I was so freaking excited at my
wonderful new discovery that I left the wire lying about where you see it
in the picture, and by the time I got around to unclipping the leads from
the wall wart plug, the wire had already melted itself into the botttom of
the small block.

The cavity that looks like a hole somebody tried to drill, who didn't know
what an ordinary drill bit will do to that type/form of styrofoam, is a
hole somebody (I) tried to drill, not knowing what an ordinary drill bit
will do to that type/form of styrofoam. ;-)

But the way the wire cut through it! I did feel the difference, but that
cut is amazing! I did that by hand! Imagine if I put it in some kind of
fixture!

BWAHAHAHAHAAAA! Styrofoam cut to your spec - $0.12 per square inch of new
surface!! ;-D ;-D ;-D

http://www.neodruid.org/images/CutFoam-640x480.jpg

BTW, if you get another server error, please, please let me know, because
as I've said, I'm inside the firewall, and I have to trust my own
blundering configurations to expose just the right stuff to the outside
world. Damn, I'm still stoned, on that one hit, and it's been a couple
hours! I might have another little hit soon though, since it _has_ been a
couple hours. %-}

Oh, yeah, before I hit "send" if you're wondering where that particular
particularly nice block of styrofoam came from, it was in a box that
somebody had shipped some big light bulbs that they've installed in the
shop. Like the size of a 1,000 watt bulb, but halogen or mercury or
something - anyway these big bulbs were packaged in these cool blocks of
foam. :) (inside corrugated cardboard boxes, of course.)

Cheers!
Rich

Us "big boys" suspend the nichrome via a spring mount, so it stays
straight as it heats and expands.

I use that scheme to bend sharp edges on various types of plastics.

...Jim Thompson
 
R

RST Engineering \(jw\)

Shucks, there are thousands of homebuilt airplanes flying today that were
cut out of styrofoam with a hot wire. It hasn't been rocket science for a
few dozen years.

Jim
 
S

Spehro Pefhany

BWAHAHAHAHAAAA! Styrofoam cut to your spec - $0.12 per square inch of new
surface!! ;-D ;-D ;-D

You can get big CNC machines that hot-wire cut big chunks of styrofoam
for POS (that's 'point of sale') displays, props and that sort of
thing.

I'm not sure you should be inhaling the fumes from that, but maybe
it's not so much worse than the other fumes you've been inhaling. ;-)


Best regards,
Spehro Pefhany
 
P

Phil Allison

"RST Engineering (jw)"
Shucks, there are thousands of homebuilt airplanes flying today that were
cut out of styrofoam with a hot wire. It hasn't been rocket science for a
few dozen years.


** Nichrome wire is NOT the best stuff to use for this job - just the
easiest due to its high resistance.

Much better to use stainless steel and exploit its positive tempco of
resistance to monitor and control the wire's temperature. If you can hold
the voltage to current ratio in the wire constant - then the temp is held
constant.

Scheme = low voltage switching regulator, wire in a bridge balance, op-amp
feedback control of PWM etc.



.......... Phil
 
R

redbelly

Oh, yeah, before I hit "send" if you're wondering where that particular
particularly nice block of styrofoam came from ...

How could we wonder about this BEFORE you hit "send"?

Mark
 
B

blah

Does anyone here have a good idea for cutting foam blocks with embedded
plastic? (Insulating Concrete Forms)

These are blocks used for construction. Two pieces of foam are connected
with plastic rebar and concrete gets poored in the middle.

Currently, most people using these cut the blocks with a chain saw/table
saw, resulting in poor cuts and major wear on the tools.

Any thoughts appreciated...the plastic makes this a little tricky. Note the
concrete only gets poored in later, so there is no need to cut through
concrete :)

Rich Grise said:
http://www.neodruid.org/images/CutFoam-640x480.jpg

Whoa, dude! I was interested in the thread about cutting styrofoam with a
hot wire. Well, some months ago I saw a hank of nichrome wire on ebay, for
a couple of bucks, which he said was #36, and just today I mic'd it [yes,
that's proper use of the apostrophe - go look it up! - Rich the Pedagogue]
at about .0047, maybe .0048. The thou on Joe's mic are like an eighth of
an inch apart, so I had to interpolate the tenths.

Anyway, in the ad that I bought it from, it said, "28 ohms per foot." I
ohmed it out, and it was within as close as I could get the probes to a
foot apart. :)

BTW, the reason I bought it is because I was entertaining fantasies of
building a THC evaporator. [still am, actually - Rich the proofreader]

But that's a different story. %-) What prompted this post is that I have a
"7.5VDC, 1A" wall wart that came with some kind of radio that somebody
threw away, a set of Radio Shack clip leads, and this nichrome wire.
"Hmm", I says to meself. Did I say I'm still stoned from that ONE HIT!??)

But I remembered that "cut foam with a hot wire?" thread, and I thought,
what's the worst that could happen? So I took a piece almost a foot long,
clipped the clip leads to the ends - you can barely see the red-booted
clip and red VOM lead, which for the pic have been disconnected. I just
clipped the wall wart to a piece of this nichrome wire, on top of a couple
of pieces of ceramic tile I'd scrounged, and it didn't get red, but it got
uncomfortably warm to the touch, like, if I'd held it tightly between
thumb and finger, it'd have left a mark in a few seconds. I don't know how
to estimate temp, but I'd say more than 120 F, but decidedly less than
450! :) So, anyways, this nichrome wire is lying there dissipating heat,
and I grabbed this styrofoam block, and picked up the wire by the clips,
and, well, I cut the styrofoam. :) It was kind of a weird feeling,
actually - I felt almost no resistance (in the mechanical sense) as if I
were cutting butter, please excuse the trite hackneyed cliche. ;-)

Just for context, in the pic you can still see the nichrome wire, and it
looks like it goes into the right-hnad corner of the small block and out
of the top corner? Well, here's the thing. I was so freaking excited at my
wonderful new discovery that I left the wire lying about where you see it
in the picture, and by the time I got around to unclipping the leads from
the wall wart plug, the wire had already melted itself into the botttom of
the small block.

The cavity that looks like a hole somebody tried to drill, who didn't know
what an ordinary drill bit will do to that type/form of styrofoam, is a
hole somebody (I) tried to drill, not knowing what an ordinary drill bit
will do to that type/form of styrofoam. ;-)

But the way the wire cut through it! I did feel the difference, but that
cut is amazing! I did that by hand! Imagine if I put it in some kind of
fixture!

BWAHAHAHAHAAAA! Styrofoam cut to your spec - $0.12 per square inch of new
surface!! ;-D ;-D ;-D

http://www.neodruid.org/images/CutFoam-640x480.jpg

BTW, if you get another server error, please, please let me know, because
as I've said, I'm inside the firewall, and I have to trust my own
blundering configurations to expose just the right stuff to the outside
world. Damn, I'm still stoned, on that one hit, and it's been a couple
hours! I might have another little hit soon though, since it _has_ been a
couple hours. %-}

Oh, yeah, before I hit "send" if you're wondering where that particular
particularly nice block of styrofoam came from, it was in a box that
somebody had shipped some big light bulbs that they've installed in the
shop. Like the size of a 1,000 watt bulb, but halogen or mercury or
something - anyway these big bulbs were packaged in these cool blocks of
foam. :) (inside corrugated cardboard boxes, of course.)

Cheers!
Rich
 
S

Spehro Pefhany

Does anyone here have a good idea for cutting foam blocks with embedded
plastic? (Insulating Concrete Forms)

These are blocks used for construction. Two pieces of foam are connected
with plastic rebar and concrete gets poored in the middle.

Currently, most people using these cut the blocks with a chain saw/table
saw, resulting in poor cuts and major wear on the tools.

Any thoughts appreciated...the plastic makes this a little tricky. Note the
concrete only gets poored in later, so there is no need to cut through
concrete :)

Assuming the plastic is something like PE, a hot wire should cut them
effectively. If it's rigid PVC rather than PE, it might kill the
operator as a side effect.


Best regards,
Spehro Pefhany
 
P

Phil Hobbs

http://www.neodruid.org/images/CutFoam-640x480.jpg

Whoa, dude! I was interested in the thread about cutting styrofoam with a
hot wire. Well, some months ago I saw a hank of nichrome wire on ebay, for
a couple of bucks, which he said was #36, and just today I mic'd it [yes,
that's proper use of the apostrophe - go look it up! - Rich the Pedagogue]
at about .0047, maybe .0048. The thou on Joe's mic are like an eighth of
an inch apart, so I had to interpolate the tenths.

Anyway, in the ad that I bought it from, it said, "28 ohms per foot." I
ohmed it out, and it was within as close as I could get the probes to a
foot apart. :)

BTW, the reason I bought it is because I was entertaining fantasies of
building a THC evaporator. [still am, actually - Rich the proofreader]

But that's a different story. %-) What prompted this post is that I have a
"7.5VDC, 1A" wall wart that came with some kind of radio that somebody
threw away, a set of Radio Shack clip leads, and this nichrome wire.
"Hmm", I says to meself. Did I say I'm still stoned from that ONE HIT!??)

But I remembered that "cut foam with a hot wire?" thread, and I thought,
what's the worst that could happen? So I took a piece almost a foot long,
clipped the clip leads to the ends - you can barely see the red-booted
clip and red VOM lead, which for the pic have been disconnected. I just
clipped the wall wart to a piece of this nichrome wire, on top of a couple
of pieces of ceramic tile I'd scrounged, and it didn't get red, but it got
uncomfortably warm to the touch, like, if I'd held it tightly between
thumb and finger, it'd have left a mark in a few seconds. I don't know how
to estimate temp, but I'd say more than 120 F, but decidedly less than
450! :) So, anyways, this nichrome wire is lying there dissipating heat,
and I grabbed this styrofoam block, and picked up the wire by the clips,
and, well, I cut the styrofoam. :) It was kind of a weird feeling,
actually - I felt almost no resistance (in the mechanical sense) as if I
were cutting butter, please excuse the trite hackneyed cliche. ;-)

Just for context, in the pic you can still see the nichrome wire, and it
looks like it goes into the right-hnad corner of the small block and out
of the top corner? Well, here's the thing. I was so freaking excited at my
wonderful new discovery that I left the wire lying about where you see it
in the picture, and by the time I got around to unclipping the leads from
the wall wart plug, the wire had already melted itself into the botttom of
the small block.

The cavity that looks like a hole somebody tried to drill, who didn't know
what an ordinary drill bit will do to that type/form of styrofoam, is a
hole somebody (I) tried to drill, not knowing what an ordinary drill bit
will do to that type/form of styrofoam. ;-)

But the way the wire cut through it! I did feel the difference, but that
cut is amazing! I did that by hand! Imagine if I put it in some kind of
fixture!

BWAHAHAHAHAAAA! Styrofoam cut to your spec - $0.12 per square inch of new
surface!! ;-D ;-D ;-D

http://www.neodruid.org/images/CutFoam-640x480.jpg

BTW, if you get another server error, please, please let me know, because
as I've said, I'm inside the firewall, and I have to trust my own
blundering configurations to expose just the right stuff to the outside
world. Damn, I'm still stoned, on that one hit, and it's been a couple
hours! I might have another little hit soon though, since it _has_ been a
couple hours. %-}

Oh, yeah, before I hit "send" if you're wondering where that particular
particularly nice block of styrofoam came from, it was in a box that
somebody had shipped some big light bulbs that they've installed in the
shop. Like the size of a 1,000 watt bulb, but halogen or mercury or
something - anyway these big bulbs were packaged in these cool blocks of
foam. :) (inside corrugated cardboard boxes, of course.)

Cheers!
Rich
Styrene monomer is massively carcinogenic, so you'll want to avoid
breathing the vapour that comes off when you cut.

Cheers,

Phil Hobbs
 
K

Ken Muldrew

blah said:
Does anyone here have a good idea for cutting foam blocks with embedded
plastic? (Insulating Concrete Forms)

These are blocks used for construction. Two pieces of foam are connected
with plastic rebar and concrete gets poored in the middle.

Currently, most people using these cut the blocks with a chain saw/table
saw, resulting in poor cuts and major wear on the tools.

A small electric chainsaw works like a charm, and any flaws can be
filled in with spray foam before the pour. There is absolutely no wear
on the tool (even if it was useful for something else, which it
isn't). If you really want an artistic cut, then one of those electric
carving knives that you sometimes see at garage sales might do the
trick.

Ken Muldrew
[email protected]
(remove all letters after y in the alphabet)
 
I

Ian Stirling

Styrene monomer is massively carcinogenic, so you'll want to avoid
breathing the vapour that comes off when you cut.

Many sources disagree - for example http://www.epa.gov/ttn/atw/hlthef/styrene.html

If it was massively carcinogenic, I'd be looking for huge amounts
of cancers from all the fiberglass boat-builders out there, often working
in poorly ventilated spaces.
 
J

John Ferrell

I believe the Polyurethane foam releases toxic gases when burnt or hot
wire cut.
Does anyone know for sure?
 
S

Spehro Pefhany

I believe the Polyurethane foam releases toxic gases when burnt or hot
wire cut.
Does anyone know for sure?

The Australian government thinks so:

http://www.nohsc.gov.au/OHSInformation/Databases/Archived/pamdetails.asp?pgmid=1372

"Recent testing has shown that when the polyurethane foam is heated or
burned, toxic fumes are released which can pose a serious threat to
the health of building workers. Fumes released contain nitrous oxides,
carbon monoxide, hydrogen cyanide, isocyanates and chlorides."





Best regards,
Spehro Pefhany
 
P

Phil Allison

"John Ferrell"
I believe the Polyurethane foam releases toxic gases when burnt or hot
wire cut.
Does anyone know for sure?


** The two part *polyurethane* foam used by boat builders is not easy to
melt.

I bet it cannot be cut with a hot wire like *polystyrene* foam can.



............ Phil
 
J

John Woodgate

I read in alt.binaries.schematics.electronic that Spehro Pefhany
The Australian government thinks so:

http://www.nohsc.gov.au/OHSInformation/Databases/Archived/pamdetails.asp
?pgmid=1372

"Recent testing has shown that when the polyurethane foam is heated or
burned, toxic fumes are released which can pose a serious threat to the
health of building workers. Fumes released contain nitrous oxides,

There are nitrous oxide N2O and nitrogen oxides (mixed) NOx. 'Nitrous
oxides' is not a term recognized in chemistry AFAIK.
carbon monoxide, hydrogen cyanide, isocyanates and chlorides."
That's obviously about burning with an inadequate oxygen supply; you
wouldn't get CO and 'nitrous oxides' from burning with adequate oxygen.

Re the 'isocyanates and chlorides', it depends very much on what they
are isocyanates and chlorides of! The whole statement reeks of 'press
office' rather than 'toxicology lab'.
 
R

Rich Grise

Many sources disagree - for example http://www.epa.gov/ttn/atw/hlthef/styrene.html

If it was massively carcinogenic, I'd be looking for huge amounts
of cancers from all the fiberglass boat-builders out there, often working
in poorly ventilated spaces.

Well, (A) I don't believe in carciongens, that's just an excuse for people
to find something to blame when they give themselves cancer, and (B) it
never got hot enough to evaporate anything - I was kind of surprised that
it cut through the plastic at all.

Thanks!
Rich
 
J

John Popelish

Rich said:
Well, (A) I don't believe in carciongens, that's just an excuse for people
to find something to blame when they give themselves cancer, and (B) it
never got hot enough to evaporate anything - I was kind of surprised that
it cut through the plastic at all.

If the Styrofoam wasn't such a good thermal insulator, the wire
probably wouldn't have gotten nearly so hot.
 
C

Chuck Harris

Rich said:
Well, (A) I don't believe in carciongens, that's just an excuse for people
to find something to blame when they give themselves cancer, and (B) it
never got hot enough to evaporate anything - I was kind of surprised that
it cut through the plastic at all.

Thanks!
Rich

Good for you Rich, unfortunately, cancer causing agents don't care what
you believe in, or what you call them.

When the wire is placed against the foam, it no longer loses its heat through
conduction into the air (because foam is a great insulator), and it quickly
heats up to the vaporizing temperature of the foam.... And fills the air with
a cloud of plastic vapor, and partially combusted plastic gorp. All of which
probably isn't good for you. It might not cause cancer, but it might plate
your lungs with plastic, which could impair their ability to uptake oxygen.

Oh yeah, that's right, you've already done that with your various vices.

Don't forget, even though styrofoam fumes smell like PCP, it isn't really,
so there is no point is whiffing the fumes.

-Chuck
 
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