Cutting Foam with a hot wire.

EPS, or Expanded Polystyrene melts and therefore can be cut with a hot wire.

Polyurethane foam can NOT be cut with a hotwire tool.

Polystyrene is commonly called Styrofoam® which is a brand name. It is also called beaded
foam. It smells like styrene. It is made when special expandable beads are heated with
steam. They expand like popcorn and stick together inside of a mold.

If you need to hard coat EPS please see Steve's Foam Coat found [Here]

You can make your own hotwire cutter with heat-wire, also called resistance wire. You can
buy it on eBay for about $12 for a short length. You'll have to figure out how to make
your own handles and wire holders. I usually use a 12 or 24 volt battery charger. By the
time you go through all the hassle and expensive you might as well buy one of the
commercially available ones we have for sale. See below.

Large blocks of foam can be custom cut at the factory. A large frame with a two axis,
computer controlled hot wire will cut the blocks into any shape you want. Round surfaces
are a big problem and are usually created by making multiple bevel cuts.

EPS is used more and more for props and sculpting armatures. In my opinion it is inferior
to urethane foam, but an excellent compromise when cost is being considered. The two main
problems with EPS in sculpting and prop making are; It will compress and it will melt
when exposed to strong solvents.

Compression means that it will get a little spongy when it starts to get heavy. This
means you will have difficulty controlling the bottom of your prop or sculpture. If you
are using a plaster type foam coating it will crack off. This is usually not a problem
with polyurethane foam.

Every artist I know has a horror story to tell about painting Styrofoam. Once I spent
several hours sculpting up some very fine props. I quickly laid on a coating of black
spray paint and went back inside the house. Later I came back only to find some little
pieces of black plastic. My first thought was someone had stolen my props (I was a kid at
the time) and just to be mean, replaced them with the little pieces of black plastic.
What really happened was my sculptures had melted. Every artist does this once. Water
based products and epoxy will not melt EPS, but a lot of other things will. Any thing in
a spray can will melt it.

I no longer have contact information for EPS suppliers. They do not want to be bothered
by the general public. Just look in the yellow pages under Foam Styrene. Please don't
call me neither I'll just tell you to look in the yellow pages under Foam Styrene.

Good Luck and have fun, Steve

FF-K02 Crafters Sculpting Tool Kit

Our most popular and versatile tool for freehand sculpting, carving and scroll cutting. The arms pivot so the wire can be taut or looped outward. The wire can be used at 8" with the arms fully extended or can be shortened to 5" for a faster cut. This tool is very popular for carving mountains and shaping designs. Includes a single-temperature plug-in-the-wall Crafters Power Supply. Features a handy on/off switch right on the handle and comes with 6' of tool cord and 6' of power supply cord, for 12' of cord total. Includes six (6) hot-wires.

The DVD takes you through all the basics of using the Sculpting Tool, plus tips on foam gluing, and painting. The bonus featurette, Magic Mountains, is a 30 minute step-by-step instruction on how to make a great looking spooky mountain diorama that can also be transformed into a snow village, or miniature gaming terrain. Making village terrain instruction sheet is also included.

CAT #	Description	Price
FF-K02	Crafters Sculpting Tool Kit	$34.95

FF-K05 - Crafters Deluxe 3-In-1 Kit

This kit includes the Sculpting Tool (with 6 hot-wires), 4" Hot Knife, Engraving Tool, single-temperature plug-in-the-wall Crafters Power Supply, and 90 minute Hot Wire Foam Factory DVD, all in a handy carrying case. Each tool features a handy on/off switch right on the handle and has 6' of tool cord and 6' of power supply cord, for 12' of cord total for each tool.

Get creative!! The Sculpting Tool is our most popular and versatile tool for freehand sculpting, carving, and scroll cutting. Making realistic hills and mountains has never been easier. Cuts foam like a hot knife through butter.

Plunge, Slice, and Dice! The Hot Knife is the foam cutting tool the world has been asking for. A combo hand held scroll saw and power drill that cuts foam with fast, clean surgical precision. The four-inch blade is made from thin tough steel, with a unique round shape that slices quickly and cleanly in any direction like magic.

It's all in the details!! The Engraving Tool is perfect for engraving bricks, blocks, stones, words, and other shapes for detailed looking walls, abutments, portals, slats, cobblestone roads, signs and more. A fine finishing tool for detailing any type of 2-D or 3-D sculpture or model. The blade is approximately 2" long, and only the tip heats up.

CAT #	Description	Price
FF-K05	Crafters Deluxe 3-In-1 Kit	$99.95

FF-K42P6 Pro 6" Hot Knife Kit

This kit includes the Pro 6" Hot Knife, adjustable Pro Power Station, 90 minute Hot Wire Foam Factory instructional DVD and everything is packaged in a sturdy toolbox large enough to accommodate all the pro tools and accessories. Simply plug the Hot Knife into the included adjustable temperature Pro Power Station and start cutting!

Our 6" Hot Knife cuts 1.5x faster than the 8" model and gets as hot as foam can be cut without losing detail and charring. It is a combo hand held scroll saw and power drill that cuts foam with fast, clean surgical precision. This tool can only be used with the Pro Power Station.

CAT #	Description	Price
FF-K42P6	Pro 6" Hot Knife Kit	$144.95

FF-K44P6 Pro 6" Hot Knife & Freehand Router Kit

Includes Pro Hot Knife with 6" Blade, Freehand Router with 5 blades, adjustable temperature Pro Power Station, 90 minute Hot Wire Foam Factory Instructional DVD, and sturdy carrying case. This kit is popular with artists doing large projects requiring fast cutting versatile foam cutting and sculpting tools.

Our 6" Hot Knife cuts 1.5x faster than the 8" model and gets as hot as foam can be cut without losing detail and charring. It is a combo hand held scroll saw and power drill that cuts foam with fast, clean surgical precision. This tool can only be used with the Pro Power Station.

Make the Blade of the Freehand Router into any shape! Comes with 5 ultra-stiff, yet shapable 10.5" wires that bolt onto the arms. Scoop out big or tiny pieces of foam for any level of control. The Freehand Router is to foam what the chisel was to stone. This tool can only be used with the Pro Power Station.

CAT #	Description	Price
FF-K44P6	Pro 6" Hot Knife & Freehand Router Kit	$164.95

FF-K47 - Pro Model 4-In-1 Kit

This kit includes all four basic tools: the Sculpting Tool, Engraving Tool, Freehand Router, and 4" Hot Knife. Plug into the adjustable temperature Pro Power Station and start cutting!

Comes with the adjustable temperature Pro Power Station, 6 hot-wires for the Sculpting Tool which are heavier than the wires used with the Crafters powered model, 5 blades with the Freehand Router, and the 90 minute Foam Factory Instructional DVD. Everything is packaged in a sturdy toolbox for all the pro tools and accessories.

CAT #	Description	Price
FF-K47	Pro Model 4-In-1 Kit	$199.95

FF-035I Industrial 6" Hot Knife

Don't blame us, you asked for it:
Smoking Fast
High Wattage
Ruthlessly Rugged
Foam Charring
Flesh Burning
Wickedly Unforgiving
Made In China (All of our other tools are Made In USA)

Unlike the cheaper models (with the same price tag) our new 6" Industrial Hot Knife can be used continuously for periods of up to 45 minutes, and much longer if turned off between cuts. It is lightweight, solid state (the power supply is right in the handle), has a replaceable 6" blade, variable heat settings, and a 10 foot power cord.

This tool is for doing fast and serious damage to your big foam projects, and to you if not used properly.

CAT #	Description	Price
FF-035I	Industrial 6" Hot Knife	$229.95

FF-035I-KIT Industrial Hot Knife Kit

Don't blame us, you asked for it:
Smoking Fast
High Wattage
Ruthlessly Rugged
Foam Charring
Flesh Burning
Wickedly Unforgiving
Made In China (All of our other tools are Made In USA)

Kit comes with Industrial Knife, 4" and 6" straight blades, Sled Guide with replaceable 12" shapeable grooving blade, four easy to hand-shape 12" round and flat blades for creative cutting, all in a sturdy Carrying Case. Unlike the cheaper models (with the same price tag) our new 6" Industrial Hot Knife can be used continuously for periods of up to 45 minutes, and much longer if turned off between cuts. It is lightweight, solid state (the power supply is right in the handle), variable heat settings, and a 10 foot power cord.

This tool is for doing fast and serious damage to your big foam projects, and to you if not used properly.

CAT #	Description	Price
FF-035I-KIT	Industrial Hot Knife Kit	$299.95

FF-050A 2x4 Foot Compound Bow Cutter

It's big! It's bad! Our 2' x 4' Compound Bow Cutter (actually a little wider than 2' and 4') will knock your block off! Our big, versatile bow cutter will get those unwieldy 4' by 8' blocks or sheets of foam knocked down to manageable sizes. Built for pros, it's fast and agile and built to last. It is 1/3 the price of other, whimpier bows, and ours is made in USA. Thick round tough rubber coated tubing makes a firm comfy grip.

It’s two, three, four bows in one. Cuts fast, wide, deep or both: configure it at 2' or 4' long by 6" or 18" deep. Changes direction of cut instantly and cleanly. Use it in the 4' mode to make your big cuts, then quickly switch it to the 2' mode for creative sculpting. Convenient switch is right on the tool. Includes variable power and internally fused commercial power supply, and four 2'+ and four 4'+ long life Hot Wire blades. Plus, we give you 3 snap-clamps for storage, or so you can turn this into a workbench cutter to accurately slice foam. Quickly collapses for shipping and storage.

CAT #	Description	Price
FF-050A	2x4 Foot Compound Bow Cutter	$199.95

FF-K41 3D TABLE - Pro 3D Scroll Table Kit

The Dream Machine! Built for professional modelers, our big, sturdy (and slick looking) 3D Scroll Table is a combination Scroll Table, Router, Lathe and Milling Machine all in one versatile tool kit. Large 24" round ABS plastic base offers a 12" high and unlimited horizontal cut.

Comes with adjustable temperature Pro Power Station, two (2) Precision Blades, two (2) 11.5" Long Blades, two (2) Reshapeable Router Blades, one (1) Reshapeable Ribbon Blade, Stationary and Traveling Fences, Router and Vertical Lathe Kits, 12 page Instruction Manual and the 90 minute Hot Wire Instructional DVD. Also includes a sturdy toolbox large enough to accommodate all the pro tools and accessories. This is by far the world's most amazing foam cutting machine. Your imagination is your only limit!

-Quick and easy straight, freehand or template cutting.
-Change direction of cut instantly.
-Includes Stationary Fence for controlled slicing.
-Long 11.5" Vertical Blades allow unlimited length horizontal cuts.
-Ultra fine Precision Blades slice foam paper-thin.
-8" Router Blades for contoured moldings of unlimited length.
-Router Blades can be bent with fingers to any shape.
-Angle adjustment of all blades is infinitely variable.
-Unique Traveling Fences for controllable complex angles.
-Vertical Lathe for cylinders, cones, dimensional columns.

CAT #	Description	Price
FF-K41	3D TABLE - Pro 3D Scroll Table Kit	$299.95

FF-028B-16 Foam Fusion (16 oz)

Our Foam Fusion is the ultimate EPS foam glue! It permeates the foam and bonds around its cells. Other glues containing solvents will dissolve foam over time, but our formula is solvent-free. Our glue is not affected by heat or cold as with glue guns. It works with most rigid foams including Styrofoam, and many soft foams. Foam Fusion bonds foam to almost any porous surface and is easy to apply - simply squeeze or brush on. Plus, Hot Wire Foam Factory tools will cut through this glue.

CAT #	Description	Price
FF-028B-16	Foam Fusion 16 oz.	$11.95

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