FW4000H Series
Large blocks, high volumes – built for production
Large and robust – for companies processing large blocks of PU, PUR, PIR, EPS, XPS or EPP efficiently in high volumes
2,000 / 2,500 mm available
Process large blocks economically in production
The FW4000H Series is a large, robust CNC Fastwire machine for processing material blocks made of PU, PUR, PIR, EPS, XPS, PE and EPP.
Thanks to the large working area, pipe insulation sections, insulation profiles, insulation elements or custom contours as well as boards in custom thicknesses can be cut economically and in high volumes.
The machine uses a fast-running cutting wire that cuts the material mechanically without heat input. The endless wire reaches speeds of nearly 300 km/h.
What can I produce?
Pipe insulation sections
Pipe insulation sections made of PU, PUR and PIR for pipe and industrial insulation – produced in series from the block.
Transport protection
Large contour-cut protective parts for bulky components – for example for wind turbine blades.
Insulation elements
Insulation elements and shaped parts from large blocks for construction, industrial plants and technical applications.
Boards
Boards in custom thicknesses cut directly from the production block.
What materials can I process?
The FW4000H Series processes foam and insulation materials as boards or blocks.
Blocks
PU, PUR and PIR are frequently processed as block material. Typical standard blocks are approximately 2,000 or 2,500 mm long.
The block can be used to cut pipe insulation sections, insulation profiles, insulation elements, custom contours or boards in custom thicknesses.
Boards
PE, EPP, XPS, stone wool and glass wool are mainly processed as board material.
Boards can be cut on the FW4000H horizontally or vertically.
Other suitable foam and insulation materials can also be processed.
How can I produce?
The FW4000H Series supports different processing methods depending on part, material and production task.
Cutting blocks
Heavy material blocks are easy to handle. Their own weight keeps them securely on the machine table during cutting, so no additional fixation is required.
Heavy blocks are easiest to load with a forklift.
Lightweight blocks, however, can be pushed by the cutting wire and must be fixed. Depending on the material, different fixation options are available.
Cutting boards
Boards can be cut horizontally or vertically.
Heavy boards remain securely on the machine table through their own weight and do not require additional fixation during cutting.
Lightweight boards, however, can be pushed by the cutting wire and must be fixed. Depending on the material, different fixation options are available.
Vertically positioned boards must additionally be stabilized against tipping sideways. A vertical board stabilization system is available for this purpose.
Several vertical boards can be positioned side by side and, for the same contour, cut in a single operation.
Cutting to length and trimming
Raw blocks often need to be brought to a defined size before further processing. Uneven end faces can be removed or required block lengths can be produced.
Several cross-cuts can also be performed consecutively. This allows a longer material block to be divided into several sections with defined lengths.
During trimming, uneven or unwanted outer areas are removed, creating clean starting surfaces for further processing.
Which machine should I choose?
The difference between the FW4020H, FW4030H and FW4040H is the length of the machine table. The FW4020H is designed for shorter materials, the FW4030H for medium lengths and the FW4040H for longer materials.
The standard working width is 1,250 mm. Working widths of 2,000 mm or 2,500 mm are also available.
As a general rule, the working width should always be selected as small as possible. As wire length increases, cutting quality and possible cutting speed decrease. If a large working width is only needed occasionally, a long wire unnecessarily limits the machine in daily operation.
| FW4020H | FW4030H | FW4040H | |
|---|---|---|---|
| X travel | 2,050 mm | 3,050 mm | 4,050 mm |
| Y travel | 1,280 mm | 1,280 mm | 1,280 mm |
| Working width | 1,250 mm | 1,250 mm | 1,250 mm |
| Optional working width | 2,000 / 2,500 mm | 2,000 / 2,500 mm | 2,000 / 2,500 mm |
| Max. material height | 1,250 mm | 1,250 mm | 1,250 mm |
| Max. material size L × W | 2,000 × 1,250 mm | 3,000 × 1,250 mm | 4,000 × 1,250 mm |
| Machine dimensions L × W | 5,500 × 2,000 mm | 7,500 × 2,000 mm | 9,500 × 2,000 mm |
| Machine height | 2,000 mm | 2,000 mm | 2,000 mm |
How fast can I cut?
Actual cutting speed depends on material, material density and the required cutting result.
The material determines the cutting speed
PIR, PU and PUR are cut at approximately 1.0–2.0 m/min, depending on material density and structure.
For stone wool, typical cutting speeds are approximately 1.0–1.5 m/min.
For EPP, PE, XPS and other foams, the usable cutting speed also depends on material type, density and the required cutting result.
For precise values, we are happy to perform test cuts with your material in our sample production facility.
Which cutting wire is used?
The FW4000H uses a fast-running cutting wire that cuts the material mechanically without heat input.
The cutting wire consists of several wire cores with another wire wound around them. Different windings are used depending on the material to achieve the best possible cutting quality and cutting speed.
The cutting wire has a diameter of 1.3 to 1.6 mm.
The standard wire length is 1,250 mm. Wire lengths of 2,000 mm or 2,500 mm are also available.
Which software is used?
A CNC machine is only as good as its software. It has a major influence on how easily and quickly the machine can be operated.
When selecting a CNC cutting machine, the focus should therefore not only be on the machine itself, but especially on the software.
Ultimately, the machine does nothing more than execute the commands generated by the software. What matters is how easily and quickly these commands can be created and transferred to the machine.
Complicated software increases job preparation time for every single order. Over months and years, this additional time adds up to significant production costs. Good software simplifies job preparation and saves time and money.
CAM software for custom contours
CAM software translates a drawing into machine commands that can be executed by the CNC machine.
The required contour is first drawn in CAD software and saved as a DXF or DWG file.
The drawing is then loaded into the CAM software, translated into machine commands and saved as a machine program.
The completed machine program is then loaded on the machine and the cutting process is started.
On our machines, CAD software, CAM software and machine software are separate. This means any suitable CAD or CAM system can be used freely.
Our own CAM software is styroCAM Fastwire. It is included for the first year.
Machine plugin for simple cuts
Simple cuts do not require a CAD drawing or CAM programming. Dimensions and machine movements can be entered directly through the machine plugin.
This allows straight cuts, rectangular contours, cutouts or miters to be created and cut directly on the machine.
What tasks can it handle in my production?
The FW4000H Series can be used both for project-based customer orders and for the advance production of regularly required products.
Produce customer orders
Different contours, dimensions and quantities can be produced directly to customer order.
This allows you to respond directly in your own production to changed dimensions, custom parts or components required at short notice.
Smaller quantities and replacement production can also be handled flexibly without having to source the required parts externally.
Produce products for stock
Regularly required products can be pre-produced and kept in stock.
Frequently required contours and standard dimensions can therefore be produced before a specific customer order is received.
This creates your own inventory and allows you to respond to new orders faster and with less dependence on external lead times.
What happens if service is required?
If service is required, support is provided directly by cnc-multitool.
Many faults can first be analyzed together by phone, email or remote support and can often be resolved immediately.
The FW4000H is designed so that important components are easily accessible and can be replaced quickly when required. After consultation with our service team, many tasks can also be carried out by your own employees.
If an on-site repair is required, a service technician can carry out the necessary work at your facility.
The objective is always to keep downtime as short as possible and return the machine to production quickly.
Machine features
The FW4000H Series is designed for reliable operation in day-to-day production. This includes a robust steel construction, a powerful wire drive and operating and safety systems designed for production use.
Robust steel construction
The FW4000H Series is built from welded and painted steel profiles. The heavy-duty construction ensures smooth machine operation and provides the basis for repeatable cutting results in day-to-day production.
At the same time, the machine table remains open and easily accessible. Material blocks and boards can therefore be positioned, aligned and removed easily.
The open design also makes loading large or heavy materials easier, for example positioning a heavy block with a forklift or heavy boards with a board lifting device.
Powerful cutting wire motor
The circulating cutting wire is driven by an especially powerful 4 kW three-phase motor.
This allows even high-density materials to be cut without the cutting wire losing speed under load or even becoming stuck.
The wire speed can be controlled directly through the machine software and adjusted to the respective material.
Pneumatic wire tensioning with wire monitoring
The cutting wire is pneumatically tensioned during operation. This keeps wire tension constant during cutting: the wire does not sag or oscillate.
This is essential for clean, smooth cut surfaces without grooves.
If the cutting wire is damaged or an unexpected event occurs in the wire path, the machine stops automatically.
After an inspection or wire change, the cutting program can be continued from the point where the machine stopped.
Enclosed cutting arms for dust control
During abrasive cutting, the circulating cutting wire saws through the material. This produces dust that is carried along by the wire. This dust must be extracted.
The machine therefore has two dust extraction connections, each 100 mm in diameter, to which the extraction system is connected. This removes the majority of the generated dust directly at the machine.
Either a dust extraction system supplied by us or a suitable external extraction system can be used.
Control PC package
Together with the machine software and control system, the computer system forms the operating environment of the FW4000H Series.
The system is prepared for machine operation and supplied with a current Windows Pro license. Computer, interfaces and software are therefore matched to each other.
All cnc-multitool computer systems include a second SSD as a backup drive.
Dust-protected operator console directly at the machine
The operator console is located directly at the FW4000H and is dust-protected for use in production environments.
Computer, monitor, keyboard, mouse and the controls required for machine operation are clearly arranged at one fixed workstation.
Machine operation, software and production documents are therefore available directly where they are needed in day-to-day production.
The operator can monitor the machine, set up the material and control the cutting process directly from the workstation at the machine.
Technical data
The most important technical data for the three machine versions in direct comparison.
| Feature | FW4020H | FW4030H | FW4040H |
|---|---|---|---|
| CNC axes | 2 | 2 | 2 |
| X travel | 2,050 mm | 3,050 mm | 4,050 mm |
| Y travel | 1,280 mm | 1,280 mm | 1,280 mm |
| Working width | 1,250 mm | 1,250 mm | 1,250 mm |
| Optional working width | 2,000 / 2,500 mm | 2,000 / 2,500 mm | 2,000 / 2,500 mm |
| Max. material height | 1,250 mm | 1,250 mm | 1,250 mm |
| Max. material size L × W | 2,000 × 1,250 mm | 3,000 × 1,250 mm | 4,000 × 1,250 mm |
| Number of cutting wires | 1 | 1 | 1 |
| Wire diameter | 1.3 – 1.6 mm | 1.3 – 1.6 mm | 1.3 – 1.6 mm |
| Max. cutting speed | up to 4 m/min | up to 4 m/min | up to 4 m/min |
| Max. positioning speed | 6 m/min | 6 m/min | 6 m/min |
| Cutting wire speed | up to 300 km/h | up to 300 km/h | up to 300 km/h |
| Cutting wire motor | 4 kW | 4 kW | 4 kW |
| Drive system | Rack / chain | Rack / chain | Rack / chain |
| Pneumatic wire tensioning | Standard | Standard | Standard |
| Wire break monitoring | Standard | Standard | Standard |
| Vacuum table | optional | optional | optional |
| Compressed air | 6 bar | 6 bar | 6 bar |
| Power supply | 400 VAC, 50–60 Hz | 400 VAC, 50–60 Hz | 400 VAC, 50–60 Hz |
| Power consumption | approx. 5,000 W | approx. 5,000 W | approx. 5,000 W |
| Machine dimensions L × W | 5,500 × 2,000 mm | 7,500 × 2,000 mm | 9,500 × 2,000 mm |
| Machine height | 2,000 mm | 2,000 mm | 2,000 mm |
| Approx. machine weight | 950 kg | 1,250 kg | 1,550 kg |
| Technical data sheet | |||
| Price plus VAT | 56.750,00 € | 60.000,00 € | 65.000,00 € |
| Request | Request | Request |
Scope of supply
The FW4000H Series is supplied as a complete production solution. Machine, control system and basic software are already included.
Included:
- FW4000H CNC Fastwire machine
- Machine control
- Control PC package
- Machine software
- Machine plugin
- styroCAM Fastwire (included for the first year)
- Dust-protected operator console
- 12-month warranty
Required equipment
Dust extraction
Fastwire cutting produces sawdust depending on the material and cutting wire. A suitable dust extraction system is therefore required for production operation.
The extraction system can be supplied by us to match the machine or provided by the customer.
A suitably integrated extraction system can be switched on and off through the machine software.
Safety system
A suitable safety system is required for machine operation.
Depending on the installation and production environment, this can consist of a safety fence and safety light barriers.
The safety system can be ordered from us or provided by the customer in accordance with the applicable safety regulations.
Options and accessories
Forklift loading
Very heavy material blocks are easiest to position on the machine with a forklift.
For this purpose, the machine table can be equipped with an integrated opening for the forklift forks. The block can then be placed directly on the machine table and positioned precisely.
This simplifies material handling and reduces manual effort when loading heavy blocks.
Roller conveyors
Long or heavy material blocks can be moved to the machine more easily with roller conveyors and transported away again after processing.
Roller conveyors make material handling in production significantly easier.
Board lifting device
For heavy or large-format boards, the FW4000H Series can be equipped with a board lifting device.
This can be used to pick up stone wool, PIR, PU or PUR boards and position them on the machine table.
The lifting device reduces physical strain on the operator and makes regular machine loading easier.
Vertical board stabilization
When boards are cut vertically, they must be stabilized against tipping sideways.
For this purpose, the FW4000H can be equipped with a vertical board stabilization system. The side stabilization panels are adjusted to the material thickness and keep the boards securely in position during cutting.
The stabilization system is removable and is only used when required for the respective process.
Vacuum table
Particularly lightweight blocks or boards can be pushed by the cutting wire and therefore require additional fixation.
For this purpose, the FW4000H Series can be equipped with a vacuum table that holds the material securely on the machine table during cutting.
This means additional mechanical fastening can be largely avoided.
Installation and commissioning
There are two options for commissioning the FW4000H Series.
On request, our technicians carry out installation and commissioning directly at the customer's site. The machine is assembled, connected, tested and handed over ready for operation.
Alternatively, the FW4000H Series can also be commissioned by the customer. We provide the relevant documentation and videos and can also support the process remotely when required.
Software and application training can also be booked at cnc-multitool, at the customer's site or online via TeamViewer.
Frequently asked questions
Which materials can I cut with the FW4000H?
The FW4000H processes different foam and insulation materials as blocks or boards. Typical block materials are PU, PUR and PIR. PE, EPP, XPS, stone wool and glass wool are mainly processed as board material.
Other suitable foam and insulation materials can also be cut. If in doubt, we can test your material with a sample cut.
What is the difference between the FW4020H, FW4030H and FW4040H?
The difference is the length of the machine table. The FW4020H is designed for shorter materials, the FW4030H for medium lengths and the FW4040H for longer materials.
Which working widths are available?
The standard working width is 1,250 mm. Working widths of 2,000 mm or 2,500 mm are also available. As wire length increases, cutting quality and possible cutting speed decrease.
Can I cut blocks and boards?
Yes. The FW4000H can process material blocks as well as boards positioned horizontally or vertically.
Several vertical boards can be positioned side by side and cut in a single operation when the contour is identical.
Do blocks need to be fixed during cutting?
Heavy material blocks remain securely on the machine table through their own weight and do not require additional fixation.
Lightweight blocks can be pushed by the cutting wire. Depending on the material, different fixation options are available.
How are heavy blocks loaded onto the machine?
Heavy blocks are easiest to load with a forklift. For this purpose, the machine table can be equipped with an integrated opening for the forklift forks.
Do boards need to be fixed during cutting?
If the boards are heavy enough, their own weight is sufficient.
Particularly lightweight boards can be pushed by the cutting wire and require additional fixation. Different fixation options, such as a vacuum table, are available.
How are vertical boards stabilized?
Vertical boards must be stabilized against tipping sideways. A vertical board stabilization system is available for this purpose.
The stabilization panels can be adjusted to the material thickness and removed when not required.
Can I divide a block into several lengths?
Yes. Several cross-cuts can be performed consecutively. This allows a longer material block to be divided into several sections with defined lengths.
Do I need CAM software?
Simple cuts do not require a CAD or CAM drawing. They can be created using the machine plugin.
CAM software is used for custom contours. It translates the drawing into machine commands.
Am I tied to a specific CAD or CAM software package?
No. CAD software, CAM software and machine software are separate on the FW4000H. This means any suitable CAD or CAM system can be used.
Our own CAM software is styroCAM Fastwire. Use is included for the first year.
What happens if there is a problem with the cutting wire?
If the cutting wire is damaged or an unexpected event occurs in the wire path, the machine stops automatically.
After an inspection or wire change, the cutting program can be continued from the point where the machine stopped.
Does the FW4000H require compressed air?
Yes. The pneumatic wire tensioning system requires 6 bar compressed air.
Do I need dust extraction?
Yes. Abrasive cutting produces dust that must be extracted.
The machine has two dust extraction connections, each 100 mm in diameter. Either a dust extraction system supplied by us or a suitable external extraction system can be used.
Is a safety system required?
Yes. A suitable safety system is required for machine operation. It can be supplied by us or provided by the customer in accordance with the applicable safety regulations.
What is the difference compared with the FW1000H?
The main difference is the available working area. With a material height of up to 1,250 mm, the FW4000H provides considerably more space for material blocks and large or vertically positioned boards.
Can I test my own material before purchasing?
Yes. Your own material can be tested during a demonstration in Ilmenau. We can check cutting wire, cutting speed and cutting quality for your specific application.
See the FW4000H live
Would you like to see how large boards and production blocks can be processed on the FW4000H?
Visit us in Ilmenau and see the machine under real production conditions. You are also welcome to bring your own material and test it together with us.
We can then determine directly which machine version, cutting wire and equipment make sense for your production.
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