Clark-Y airfoil template for hot wire foam cutting

thingiverse

This set of Clark-Y airfoil sections serves as a versatile template for hot wire foam cutting, allowing users to easily modify dimensions using a slicer. Initially designed with a 200mm chord length, these templates can be scaled up or down in the slicer, making them adaptable to various projects. To ensure stability during cutting, it is recommended to attach each section to a flat surface using double-sided carpet tape or by attaching a block that can be screwed into place. This will prevent movement and promote clean cuts. The basic airfoil template features screw holes for securing foam in place, while other variations offer additional design options. For example, users can create separate top and bottom sections along the chord length to accommodate channels, which can then be glued together. A top section with notches allows for customizable channel placement, and a complete airfoil template comes with pre-drilled squares for easy access. When printing in PLA, it is advisable to wrap a strip of aluminum tape around the outside edge of the template to prevent plastic from catching during cutting. Alternatively, users can print in PLA and attach 3mm plywood to the template using glue, trimming it to fit and sanding it level to create a smooth surface. This will help prevent the wire from digging into the foam. For creating round channels, users can insert a wooden or similar object into one of the pre-drilled square holes and drill out the resulting channel guide. Alternatively, they can use 3mm plywood glued to the template and then drill through it. The dimensions of these templates can be easily adjusted using the slicer's resize feature, allowing users to modify all dimensions first before changing the thickness of the template by resizing only the Z-axis. This approach ensures accurate scaling without compromising the overall design. As a resourceful community, modelers will appreciate this easy-to-use and accurate starter template, which originated from Airfoiltools.com and was imported into Freecad for editing and customization.