Hand Held Foam Cutter

thingiverse

This is my handheld battery-operated foam cutter that I designed to shape my terrain pieces. The handle is crafted to hold two pieces of M6 threaded rod bent into shape. Using four nuts and four washers allows you to attach a length of nichrome wire, which I used 28-gauge for since it was what I had on hand. In the handle, there's room to connect wires to each piece of M6 rod for power supply. The handle is held together by four M4x20mm bolts and nuts. The box serves as a storage container that holds some li-ion batteries, a balance/charge board, and a dc pwm speed controller. It features holes for the knob of a pwm board, a dc jack for charging, and an aviation plug for connecting to the cutter itself. The lid and powerbox contents are hot-glued in place since I was too lazy and in a hurry to add screw holes. My battery is composed of three 18650 cells connected in series. Some links to the components used can be found below: [Battery controller](https://www.aliexpress.com/item/4000354337413.html?spm=a2g0o.productlist.0.0.19c07782oZc5UD&algo_pvid=9f127715-c1f1-46b4-a403-a860b69d5897&algo_expid=9f127715-c1f1-46b4-a403-a860b69d5897-25&btsid=0be3743b15885864231235460efc9d&ws_ab_test=searchweb0_0,searchweb201602_,searchweb201603_) [Nichrome wire](https://www.aliexpress.com/item/32799524515.html?spm=a2g0o.productlist.0.0.63861bb6lSmoPz&algo_pvid=3fd566dd-f79e-4fc6-a13c-ac7b7cce8e4b&algo_expid=3fd566dd-f79e-4fc6-a13c-ac7b7cce8e4b-0&btsid=0be3743b15885866522581978efc9d&ws_ab_test=searchweb0_0,searchweb201602_,searchweb201603_) [PWM speed controller](https://www.aliexpress.com/item/32945688578.html?spm=a2g0o.productlist.0.0.5f751498YZ6DwM&algo_pvid=bdcd2b13-0d02-4e20-970a-bb5a48d70e21&algo_expid=bdcd2b13-0d02-4e20-970a-bb5a48d70e21-2&btsid=0be3743b15885867232163745efc9d&ws_ab_test=searchweb0_0,searchweb201602_,searchweb201603_) [DC Jack and plug](https://www.aliexpress.com/item/32837700581.html?spm=a2g0o.productlist.0.0.721d7762fvL2AA&algo_pvid=847a0cf7-24b4-41c0-b18f-b0d643975dd9&algo_expid=847a0cf7-24b4-41c0-b18f-b0d643975dd9-23&btsid=0be3743b15885867731585322efc9d&ws_ab_test=searchweb0_0,searchweb201602_,searchweb201603_)