Plastic Bender

thingiverse

This plastic bender, designed for shaping acrylic pieces, features a flat platform with a groove that accommodates a nichrome heating wire. An edge guide ensures square bends if necessary, while the maximum bend width is approximately 14 inches. Included are 3D CAD files from Solidworks 2010, though these are minimal in size. The parts were created to be laser-cut by Ponoko and adhere to their P3 sheet format. Laser-cut MDF from the US Ponoko hub's .251" thickness is recommended. The small grooves engraved on the parts align with anchor holes for steel springs that secure the heating wire. Four wood screws hold the guide in place, while a PDF pattern bends two springs for maintaining nichrome tension and straightness at 17-inch intervals. R/C airplane wheel collars clamp lead wires to the nichrome, and insulation using aluminum foil and Kapton tape is necessary to protect the MDF from burning. Any hot wire foam cutter power supply, operating between 12V DC or AC up to 10A, can be utilized with this device, with various DIY designs available online.