Hot wire cutter attachment

grabcad

I had to think outside the box when creating "shadow boards" from foam, so I came up with a creative solution. To achieve low voltage and high current through nichrom wire, I built a high current cascading step down transformer that really worked well. I repurposed some scrap material and crafted a dovetail in a block to attach it securely to the Bridgeport milling machine using a proto-track. Next, I carefully traced a profile and used the machine to cut the foam with smooth edges perfect for use in a clean space environment.