Home Built Hot Wire CNC Foam cutter
Day 1 - Vertical Y Axis
Day 2 - Horizontal X Axis
Day 3 - Lead Screw
Day 4 - Electronics
Day 5 - Finalizing the machine
Other CNC foam cutters
A New Design - Hot wire CNC Foam cutter
Foam Sample Cuts
Foam Cutting Videos
Links - RC stuff, Stepper Motors, Lead Screws
More information - about stepper motors

DIY Mach3 with Joystick and gamepad
FoamLinx Site - Foam Cutting CNC Machines
CNCLinx Site - CNC Router Tables
Foam Cutting Services - EPP, EPS, XPS
All About Foam Forum - Beta
Composites Prototyping and Design
Large and Configurable CNC Machines *
Online Store

How to coat EPS foam (Crown Moldings)
How to build an EPS Foam Recycler
How to build an EPS base and Cap cutter
How is EPS manufactured - molded
How to make RC foam planes
How to cut EPS, XPS, EPP foam
How to cut Polyurethane foam ( PU )
How to cut Acrylics - Laser cutting
DIY CNC Foam Cutter Blog - New

What is - more info about foam
What is EPS foam
What is XPS foam
What is EPP foam - Expanded Polypropylene
What is PE foam - Polyethylene foam
What is Polyurethane foam
What is Memory Foam



Expanded Polypropylene (EPP) Foam

EPP is made in a multi-step process that begins by combining polypropylene resin with
special additives, then processing the material to form individual plastic beads, which
may range from 4mm to 6mm in diameter, depending on the grade. These individual
beads are then injected into a steam chest mold, where the individual beads are fused
together under steam heat and pressure.
The resulting moulded product is a remarkably durable, yet resilient solid material.
EPP foam is flexible (semi-rigid) and light in weight, and was originally designed for
automotive energy management applications, and for computer packaging as a
cushioning material. EPP absorbs energy over and over again without denting or breaking.

EPP is a closed cell foam. It is effective across a wide temperature range (-40 to +100)
and has high chemical resistance to petrol, acetones and most chemicals found around the
shop or home. EPP is virtually unaffected by exposure to water, and is extremely buoyant,
which makes it useful in marine applications.

EPP is environmentally friendly. It can be recycled easily, and no toxic chemicals are used in its manufacture.

While EPP closely resembles expanded polystyrene, the white foam sometimes used in packaging,
there is no comparison in structural strength. EPP is used for a range of applications in the automotive
industry for components such as energy absorbers in bumpers, side impact protection, column covers,
knee protection, seating structures, consoles, tool kits, parcel shelves and more.

EPP can be cut with a saw or hot wire.
Cutting EPP with a hot wire is similar to cutting EPs with a hot wire but slower. At high densities EPP will tent to melt
So try to keep the temperature of the cutting wire as low as possible, and also the cutting speed should be slow.
Typically EPP cutting speed is about 10"/min where EPS can be 20 to 40"/min