CUT1600S
for EPS, XPS and EPP sheets
Compact 4-axis CNC hot wire cutting machines for sheets and small blocks CNC-controlled cutting of straight, tapered and twisted contours with a single cutting wire.
up to 1,250 mm
Y: 600 mm
Compact 4-axis technology for sheets and small blocks
The CUT1600S Series was developed for CNC-controlled machining of EPS, XPS and EPP sheets as well as smaller workpieces and blocks.
Four CNC axes enable both parallel cuts and cuts in which the two sides of the cutting wire move independently of each other.
This allows not only straight 2D contours but also tapered and twisted contours with different geometries on both sides of the workpiece to be produced.
The series consists of two versions: the CUT1610S with fixed machine table and the CUT1610SV with variable machine table, variable wire length and standard arm support.
Highlights
Product highlights
- 4 axes: four CNC-controlled cutting axes
- Flexible: axes can be controlled in parallel or independently
- Contours: straight, tapered and twisted cuts
- Materials: EPS, XPS and EPP sheets
- Compact: designed for sheets and smaller workpieces
Service highlights
- Tested: assembly, adjustment and functional testing at our factory
- Pre-assembled: supplied in transport-optimized assemblies
- Support: technical assistance by email and phone
- Training: available online or on site
- Commissioning: optionally by our service technician
Standard equipment
- 4-axis CNC hot wire cutting machine
- Single-wire cutting system
- Four CNC-controlled axes
- Machine table with support plate
- Mechanical wire tensioning with springs
- Machine controller
Suitable materials
EPS
EPS sheets and smaller workpieces for profiles, packaging and lightweight components.
XPS
XPS sheets for letters, logos, models and design objects.
EPP
EPP sheets for model making, drone and model aircraft wings as well as packaging.
Typical applications
2D cuts / profiles
CNC-controlled cutting of straight contours and profiles from EPS, XPS and EPP sheets.
4-axis cuts
Cut different contours on both sides of the workpiece using four independently controlled CNC axes.
Sheet cutting
Trim individual sheets or cut them to the required thickness.
Cutting to length
Cut sheets and smaller workpieces to the required length.
What our customers produce
Letters & logos
Contour-cut letters and logos made from XPS.
Models
Models and individual contours made from EPS and XPS.
Wings
4-axis-cut wings made from EPP.
Packaging inserts
Contour-cut inserts and protective parts.
Profiles
Straight and contoured profiles made from sheet material.
Design objects
Free contours and custom design components.
Prototypes
Individual parts and samples for development and testing.
Small series
Repeatable cuts for small production runs.
We prefer cutting XPS on three small CUT1610S machines rather than on one large machine. This allows us to remain flexible while producing larger quantities at the same time.
Schilling Modellbau
Which machine is right for your application?
CUT1610S
The CUT1610S has a fixed machine table and a fixed wire length of 1,250 mm.
It is the right choice for straight cuts, 2D contours and standard tapered and twisted 4-axis cuts.
If workpieces with similar dimensions are processed most of the time and extreme twists are not required, the CUT1610S provides a compact and economical solution.
CUT1610SV
The CUT1610SV features a variable machine table and a variable wire length from 400 to 1,250 mm.
The decisive advantage becomes apparent with short workpieces with a high degree of twist, for example wings. The longer the free cutting wire, the greater the required axis travel for strongly differing contours.
With short workpieces and extreme twisting, a wire length of 1,250 mm can therefore mean that the available X-axis travel is no longer sufficient. By shortening the wire length, the geometry can be moved much more compactly.
A free wire length that is as short as possible is also advantageous when cutting XPS and EPP. XPS in particular is sensitive to long wire lengths, as these can cause waves and poorer cutting quality.
Commercial production
The CUT1600S Series is designed for CNC-controlled machining of standard EPS, XPS and EPP sheets up to 1,200 × 600 mm.
With its four CNC axes, both 2D cuts and profiles and 4-axis cuts with different contours on both sides of the workpiece can be produced. In addition to contour cutting, the machine can also be used for conventional processing operations such as trimming sheets, cutting them to the required thickness and cutting them to length.
The CUT1610S operates with a fixed machine table. For greater flexibility with different workpiece widths, the CUT1610SV is available with variable machine table, variable wire length and standard arm support.
This makes the CUT1600S Series suitable for recurring, repeatable production tasks using standard sheets and smaller workpieces.
CUT1600S Series – compact 4-axis CNC technology for EPS, XPS and EPP
Machine design
The CUT1600S Series combines a compact steel construction with four CNC-controlled axes and a single cutting wire.
The two sides of the cutting wire can move in parallel or independently of each other. This makes it possible to cut conventional 2D contours as well as tapered and twisted geometries.
The CUT1610S has a fixed machine table. On the CUT1610SV, the distance between the two machine sides can be adjusted and the wire length adapted accordingly to the workpiece.
Four independently controlled CNC axes
The CUT1610S and CUT1610SV have four CNC-controlled cutting axes. The two sides of the cutting wire can move in parallel or independently of each other.
Parallel movement produces conventional 2D contours and straight cuts. Independent axis movement allows different contours on both sides of the workpiece to be connected.
This also enables tapered and twisted 4-axis cuts.
Fixed machine table – CUT1610S
The CUT1610S is supplied as standard with a fixed machine table with support plate.
The table provides a defined support surface for sheets and smaller workpieces and allows easy positioning of the material within the machine working area.
The fixed machine width results in a cutting wire length of 1,250 mm.
Variable machine table – CUT1610SV
The CUT1610SV is supplied as standard with a variable machine table.
The distance between the two machine sides can be adjusted. This allows the cutting wire length to be flexibly adjusted between 400 and 1,250 mm to different workpiece widths and cutting tasks.
The CUT1610SV also features an arm support as standard.
Wire mounting with spring tension
The cutting wire is held between the cutting arms using mechanical spring tension.
The spring compensates for changes in wire length during cutting and keeps the wire tensioned.
The cutting wire can be attached and removed without tools.
4-axis CNC controller
The machine is controlled by a 4-axis CNC controller.
In combination with the USB software package, the CNC cutting programs are transferred from a Windows PC to the machine and executed.
With the optional relay box, the cutting wire can additionally be switched on and off directly via the machine software.
Equipment and options
A power supply for the cutting wire and machine software are required to operate the CUT1610S and CUT1610SV. In addition, the machine can be equipped with additional components to suit the respective workplace and application.
Power supply with automatic current regulation
The power supply provides the cutting wire with the electrical power required for cutting.
Automatic current regulation adjusts the current supply and keeps the heating power of the cutting wire as constant as possible even when the wire length changes.
The power supply is required to operate the machine.
USB machine software package
The USB software package connects the Windows PC to the CNC controller of the machine and handles execution of the cutting programs.
The package includes the Mach3 machine software and the USB controller. The software interface is configured for operation of the 4-axis hot wire cutting machine.
Relay box
The optional relay box is connected to the machine controller and automatically switches the cutting wire on and off via a software command.
This allows the cutting wire to be switched on and off directly as part of the program sequence.
Work console
The optional work console positions the monitor, keyboard and mouse directly at the machine.
The machine controller and power supply can also be integrated into the work console. This creates a compact and tidy machine workstation.
Computer package
We can optionally supply the CUT1600S Series with a Windows PC prepared for CNC operation.
The package includes a Windows PC, monitor, keyboard and mouse. The required machine software is installed and configured for the machine by us.
Arm support
The arm support additionally stabilizes the two cutting arms and relieves the machine construction when higher wire tension is used.
It is particularly useful for demanding twisted 4-axis cuts.
The arm support is available as an option for the CUT1610S. On the CUT1610SV, it is included as standard.
Enclosure with extraction connection
The CUT1610S can be equipped with a closed machine enclosure.
The enclosure surrounds the working area and can be combined with an extraction connection through which fumes generated during cutting can be removed from the machine area.
Transparent doors continue to provide a clear view of the cutting process and easy access to the working area.
Cutting wire and springs
Cutting wire is a consumable and can be replaced quickly and without tools when required.
The wire costs approximately €1 per metre and has a very long service life under normal operating conditions. In our experience, many CUT1610S customers use less than 100 metres of cutting wire per year.
Replacement takes approximately 2 minutes. Replacement wire and suitable springs are available as accessories.
Required and supplementary equipment
Machine operation
- Power supply for the cutting wire
- Machine software
Computer & operation
- Work console
- Computer package
- Relay box for switching the cutting wire on and off via software
Program creation
- CAM software
- styroCAM optionally available
Technical Data
| Model | CUT1610S | CUT1610SV |
|---|---|---|
| Travel forward/backward (X) | 1.280 mm | 1.280 mm |
| Travel up/down (Y) | 600 mm | 600 mm |
| Wire length | 1.250 mm | variable, 400-1.250 mm |
| Max. material size (L × W × H) | 1.250 × 1.250 × 600 mm | 1.250 × 1.250 × 600 mm |
| Number of wires | 1 | 1 |
| Number of axes | 4 | 4 |
| Drive type | Lead screw drive | Lead screw drive |
| Max. travel speed | 900 mm/min | 900 mm/min |
| Cutting speed | 350–500 mm/min | 350–500 mm/min |
| Wire diameter | 0,35 mm | 0,35 mm |
| Variable wire length | no | standard |
| Arm support | optional | standard |
| Power supply | 110–220 VAC, 50–60 Hz | 110–220 VAC, 50–60 Hz |
| Power consumption | approx. 300 W | approx. 300 W |
| Installation dimensions (L × W × H) | approx. 1.800 × 1.900 × 1.550 mm | approx. 1.950 × 1.920 × 1.550 mm |
| Max. weight | 150 kg | 160 kg |
| Warranty | 12 months | 12 months |
| Price excl. VAT | 6.950,00 € | 8.250,00 € |
| Request | Request |
Scope of delivery
CUT1610S and CUT1610SV are assembled, adjusted and function-tested at our factory. For transport, the machines are supplied in transport-optimized assemblies. On site, only the machine table needs to be assembled, the machine aligned and the electronics connected.
Basic machine
- CUT1610S or
CUT1610SV CNC cutting machine - 4-axis CNC controller
- 1 cutting wire
- Wire tensioning springs
- Operating manual
Supplementary equipment
- Power supply for the cutting wire
- USB machine software package
- Relay box
- Work console
- Computer package
- CAM software
Assembly & commissioning
- Machine assembled and tested at the factory
- Supplied in transport-optimized assemblies
- Simple assembly at the installation site
Software
The CUT1600S Series is not tied to any particular drawing or CAM software. Existing vector, CAD or CAM solutions can continue to be used to create contours and cutting programs.
The basic workflow is simple: create the drawing, generate the cutting program, load the ISO G-code into the machine software and execute the cut on the machine.
From design to finished cut
The typical workflow consists of four steps.
1. Drawing: The required contour is created in vector or CAD software or imported from an existing drawing.
2. CAM / G-code: The drawing is converted in styroCAM or another suitable CAM solution into a CNC cutting program.
3. Machine control: The finished ISO G-code program is loaded into the machine software and transferred to the CNC controller of the machine.
4. Cutting: The machine executes the cutting program with its four CNC axes. With the optional relay box, the cutting wire can automatically be switched on and off via a software command.
Vector software
Any suitable vector software can be used for free 2D contours.
This can be used to create contours, profiles, letters and other free geometries and export them for further processing.
We recommend CorelDRAW as vector software. Suitable file formats for further processing include DXF and PLT.
CAD software
Any suitable 2D or 3D CAD software can be used for dimensionally accurate technical drawings and custom geometries.
The CAD data is then transferred to the CAM software and converted there into a cutting program for the machine.
This allows existing CAD software within the company to continue to be used.
styroCAM
styroCAM is our CAM software for creating CNC cutting programs for the CUT1600S Series.
The software processes the contour data and calculates the machine movements for the cutting wire.
- Import of DXF, DWG and PLT files
- Calculation of 2D contours
- Calculation of 4-axis cuts
- Output as ISO G-code
- Direct workflow from drawing to machine program
styroCAM is optional. CUT1610S and CUT1610SV can also be operated with other suitable CAM solutions.
Machine software
The machine software executes the completed CNC cutting programs.
The previously generated ISO G-code program is loaded into the machine software and transferred from there via the USB controller to the 4-axis CNC controller of the machine.
As standard, we supply Mach3 for this purpose with an operating interface configured for the CUT1600S Series.
Frequently asked questions
Which materials can the CUT1600S cut – and which cannot?
Suitable materials include thermally cuttable foams such as EPS, XPS and EPP. EPP can be processed up to a density of approximately 40 kg/m³.
Non-melting insulation materials such as mineral wool, PIR or PUR cannot be cut with hot wire. Our CNC cold wire series (FW) is designed for these materials.
Can EPP be cut cleanly?
Yes. EPP can be cut with hot wire provided that the material is suitable. The CUT1600S Series is designed for EPP up to approximately 40 kg/m³.
For good cutting quality, the free wire length should be as short as possible and adapted to the workpiece width. The optimum cutting parameters depend on the specific EPP material.
What is the difference between CUT1610S and CUT1610SV?
The CUT1610S has a fixed machine table and a fixed wire length of 1,250 mm. The arm support is optionally available.
On the CUT1610SV, the machine table is variable and the wire length can be adjusted between 400 and 1,250 mm. The arm support is included as standard on this model.
How large can workpieces and blocks be?
The maximum material dimensions are approximately 1,250 × 1,250 × 600 mm (L × W × H).
The CUT1600S Series is therefore designed for sheets, smaller workpieces and small blocks.
Which contours are possible with four axes?
With parallel movement of the four CNC axes, straight 2D contours, profiles and cuts can be produced.
When the two sides of the cutting wire move independently of each other, tapered and twisted cuts with different geometries on both sides of the workpiece are also possible.
Am I tied to specific software?
No. CUT1610S and CUT1610SV are not tied to any particular vector, CAD or CAM software.
styroCAM or another suitable CAM solution can be used to create the programs. The generated CNC cutting programs are then executed using the machine software.
Can I use my own drawings?
Yes. Your own drawings can be created in vector or CAD software and then converted into a CNC cutting program using suitable CAM software.
styroCAM processes DXF, DWG and PLT files, among others, and generates ISO G-code for the machine.
How is consistent cutting quality maintained?
The power supplies feature automatic current regulation. This controls the current supplied to the cutting wire and compensates, among other things, for changes in wire length and fluctuations in the mains voltage.
This keeps the heating power of the cutting wire as constant as possible during cutting.
What power supply does the machine require?
CUT1610S and CUT1610SV can be operated with 110–220 VAC, 50–60 Hz. Power consumption is approximately 300 W.
Do I need extraction?
In normally ventilated rooms, a separate extraction system is generally not required for operation of the CUT1600S Series.
Depending on the material processed, production volume and local conditions, additional ventilation or extraction may be advisable or required.
A machine enclosure with extraction connection is available for the CUT1610S. This allows fumes generated during cutting to be removed from the working area.
The applicable local occupational safety, environmental and building regulations must be observed.
How often does the cutting wire need to be replaced and what does it cost?
The cutting wire is a consumable but has a very long service life under normal operating conditions.
The wire costs approximately €1.00 per metre and can be replaced in a few minutes. In our experience, many customers use significantly less than 100 metres of cutting wire per year.
What is included in the scope of delivery and how is the machine assembled?
CUT1610S and CUT1610SV are assembled, adjusted and function-tested at our factory.
For transport, the machines are packed in transport-optimized assemblies and supplied on a disposable pallet. On site, only the machine table needs to be assembled, the machine aligned and the electronics connected.
What warranty is provided?
We provide a 12-month warranty for CUT1610S and CUT1610SV.
Experience the CUT1600S Series live
Visit us in Ilmenau for a demonstration of the CUT1600S Series. We will be happy to show you the machine in operation and explain the differences between CUT1610S and CUT1610SV.
On request, we can test your own materials, drawings or cutting contours and determine the appropriate machine configuration together with you.
We can also advise you on the required control, computer and CAM equipment.
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