FW4000H Series
Cut blocks – even in low-ceiling workshops
Only 2.2 m operating height – for blocks and boards made of PU, PUR, PIR as well as stone wool and glass wool, where ceiling height is limited.
optional 2,000 / 2,500 mm
The block machine for low-ceiling workshops
The FW4000H Series is a CNC Fastwire cutting machine for material blocks made of PU, PUR, PIR as well as boards made of stone wool, glass wool, and other foam and insulation materials. With an operating height of only 2.2 m it also fits in workshops with a ceiling height from 3,500 mm.
From the block you produce pipe sections, insulation profiles, insulation elements, and custom contours as well as boards in the desired thickness – economically and in series.
The FW4000H processes boards lying flat and – with the vertical board stabilization – also standing upright, so that several identical contours are produced in a single operation.
Like all Fastwire machines, it works abrasively: a fast-rotating continuous wire cuts the material mechanically and without heat input and reaches speeds of nearly 300 km/h.
What can I produce?
Pipe sections
Pipe sections from PU, PUR, and PIR for pipe and equipment insulation – produced in series from the block.
Transport protection
Large, contour-cut protective parts for bulky components – for example for rotor blades of wind turbines.
Insulation elements
Insulation elements and molded parts from large blocks for construction, equipment, and technical applications.
Boards
Boards in custom thickness cut directly from the production block.
Which 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.
From the block you can cut, for example, pipe sections, insulation profiles, insulation elements, custom contours, or boards in the desired thickness.
Boards
PE, EPP, XPS, stone wool, and glass wool are predominantly processed as board material.
On the FW4000H, boards can be cut lying flat or standing upright.
In addition, other suitable foam and insulation materials can also be processed.
How can I produce?
The FW4000H Series supports different processing methods, depending on the component, material, and production task.
For production runs that mainly process EPS (Styrofoam), our hot-wire cutting machines are the specialized solution.
Cutting blocks
Heavy material blocks are easy to handle. Thanks to their own weight, they remain securely on the machine table during the cutting process and do not need to be fixed in place additionally.
For direct loading with a forklift, a fork tine opening in the machine table is optionally available.
Cutting boards
Boards can be cut lying flat or standing upright.
Thanks to their own weight, heavy boards remain securely on the machine table during the cutting process and do not need to be fixed in place additionally.
Boards standing upright must additionally be stabilized against tipping sideways. A vertical board stabilization is available for this.
Several upright boards can be positioned side by side and, with the same contour, cut in a single operation.
Cutting to length and trimming
Before the actual processing, raw blocks often need to be brought to a defined dimension. This can, for example, remove uneven end faces or produce the required block lengths.
It is also possible to perform several cut-to-length cuts in succession. This makes it possible to divide a longer material block into several sections with defined lengths.
During trimming, uneven or unneeded outer areas are removed, creating clean reference surfaces for further processing.
Which machine should I choose?
The difference between the FW4120H, FW4125H, and FW4130H lies in the length of the machine table. The FW4120H is designed for material up to 2,000 mm, the FW4125H for standard blocks up to 2,500 mm, and the FW4130H for material up to 3,000 mm.
The standard working width is 1,250 mm. Working widths of 2,000 mm or 2,500 mm are also possible.
As a rule, the working width should always be chosen as small as possible. As the working width increases, cut quality and possible cutting speed can decrease. If a large working width is only rarely needed, it unnecessarily limits the machine in daily use.
| FW4120H | FW4125H | FW4130H | |
|---|---|---|---|
| Working area L × W | 2,000 × 1,250 mm | 2,500 × 1,250 mm | 3,000 × 1,250 mm |
| Working height | 1,250 mm | 1,250 mm | 1,250 mm |
| Footprint L × W | 5,500 × 2,000 mm | 6,500 × 2,000 mm | 7,500 × 2,000 mm |
How fast can I cut?
The material determines the cutting speed
How fast you can cut depends on material, density, contour, and cutting wire and cannot be stated as a blanket figure.
For reliable values, we are happy to carry out sample cuts with your material in our sample production.
Which cutting wire is used?
The FW4000H works with a fast-rotating cutting wire, which cuts the material mechanically and without heat input.
The cutting wire consists of several wire cores, around which another wire is wound. Depending on the material, different windings are used to achieve the best possible cut quality and cutting speed.
The cutting wire used has a diameter of 1.3 to 1.6 mm.
Which software is used?
A CNC machine is only as good as its software – it determines how quickly and easily jobs can be prepared. Good software saves time and money in day-to-day production.
CAM software for custom contours
A CAM software translates a CAD drawing (DXF or DWG) into a machine program that is loaded and cut on the machine.
With us, CAD, CAM, and machine software are separate – you can use any suitable CAM software. Our own styroCAM Fastwire is included for the first year.
Machine plugin for simple cuts
For simple cuts – straight cuts, rectangular contours, cutouts, or miter cuts – a plugin is available directly at the machine, with no CAD or CAM at all.
The operator enters dimensions and travel movements directly; the machine travels the path and then stops automatically.
What happens in a service case?
In a service case, you receive support directly from cnc-multitool – by phone, email, or remote maintenance, so many questions can be resolved immediately.
Important components are easily accessible and quick to replace; if needed, a service technician comes on site. The goal is always to keep downtime as short as possible.
Machine features
The design of the FW4000H Series is built for reliable work in daily production operation. This includes a sturdy steel construction, a powerful wire drive, and operating and safety systems tailored to everyday production.
Sturdy steel construction
The FW4000H Series is built from welded and painted steel profiles. The solid construction ensures smooth machine operation and forms the basis for repeatable cutting results. The low overall height of 2,200 mm in operation allows installation even in workshops with a ceiling height from 3,500 mm.
The open machine table remains easily accessible: material blocks and boards can be easily positioned, aligned, and removed again – a heavy block, for example, with a forklift.
Powerful cutting wire motor
The rotating cutting wire is driven by a particularly strong 4 kW three-phase motor. This makes it possible to cut even high-density materials without the wire losing speed under load or getting stuck.
The wire speed is controlled directly via the machine software and adapted to the respective material.
Pneumatic wire tension with wire-break shutoff
During operation, the cutting wire is tensioned pneumatically. The constant tension prevents sagging and vibration – a prerequisite for clean, smooth cut surfaces without grooves.
If the wire is damaged or an unexpected event occurs in the wire run, the machine stops automatically. After a check or wire change, the program resumes at the stopping point.
Enclosed cutting arms for dust protection
Abrasive cutting produces dust depending on the material, which must be extracted. For this, the cutting arms are enclosed and prepared with two 100 mm dust extraction ports.
You can use a dust extraction system offered by us or a suitable external dust extraction.
Control PC package
The computer system, together with the machine software and controller, forms the operating environment of the FW4000H. It is delivered ready to operate with a current Windows Pro license – computer, interfaces, and software are matched to one another.
All computer systems from cnc-multitool feature a second SSD as a backup drive.
Dust-protected control desk directly at the machine
The control desk sits directly at the FW4000H and is designed to be dust-protected for the production environment. Computer, monitor, keyboard, mouse, and the controls are arranged at a fixed workstation.
This gives the operator the machine, software, and production documents right where they are needed – and control of the cutting process from the workstation at the machine.
Technical data
The most important technical data of the three machine variants in a direct comparison.
| Feature | FW4120H | FW4125H | FW4130H |
|---|---|---|---|
| Working area L × W | 2,000 × 1,250 mm | 2,500 × 1,250 mm | 3,000 × 1,250 mm |
| Working height | 1,250 mm | 1,250 mm | 1,250 mm |
| Cutting wire speed | up to 300 km/h | up to 300 km/h | up to 300 km/h |
| Power supply | 400 VAC, 50–60 Hz | 400 VAC, 50–60 Hz | 400 VAC, 50–60 Hz |
| Footprint L × W | 5,500 × 2,000 mm | 6,500 × 2,000 mm | 7,500 × 2,000 mm |
| Machine height (rest / operating) | 2,000 / 2,200 mm | 2,000 / 2,200 mm | 2,000 / 2,200 mm |
| Machine weight approx. | 950 kg | 1,100 kg | 1,250 kg |
| Technical data sheet | |||
| Price excl. VAT | 56.750,00 € | 58.000,00 € | 59.500,00 € |
| Request quote | Request quote | Request quote |
Scope of delivery
The FW4000H Series is delivered as a ready-to-operate CNC Fastwire cutting machine. The machine, controller, and basic software are already included.
Included are:
- FW4000H CNC Fastwire cutting machine
- Machine controller
- Control PC package
- Machine software
- Machine plugin
- styroCAM Fastwire (included for the first year)
- Dust-protected control desk
- 12 months warranty
Required equipment
Dust extraction
Fastwire cutting produces saw dust depending on the material and cutting wire. For production operation, a suitable dust extraction is therefore required.
The dust extraction can be obtained from us to match the machine or provided by the customer.
A correctly integrated dust extraction can be switched on and off via the machine software.
Safety guard
A suitable safety guard is required for machine operation.
Depending on the setup and production environment, this may consist of a safety fence and safety light barriers.
The safety guard can be ordered from us as well or implemented by the customer in accordance with the applicable safety regulations.
Options and accessories
Forklift loading
Particularly heavy material blocks are most easily positioned on the machine with a forklift.
For this, the machine table can be equipped with an integrated opening for the fork tines. The block is set down directly on the table and then positioned exactly – this simplifies material handling and reduces the manual effort involved in loading.
Vertical board stabilization
When boards are cut standing upright, they must be stabilized against tipping sideways. For this, the FW4000H can be equipped with a vertical board stabilization whose lateral stabilization walls are adapted to the material thickness.
The stabilization is removable and is only used when it is needed for the respective processing.
Vacuum table
Particularly light blocks or boards can be displaced by the cutting wire and must be fixed in place additionally. For this, the FW4000H Series can be equipped with a vacuum table that securely holds the material on the machine table during the cutting process.
This makes it possible to largely do without additional mechanical fastenings.
Installation and commissioning
You usually commission the FW4000H yourself – for this we provide you with documentation and videos and support you via remote service if needed.
On request, our technicians take over installation and commissioning directly at your site – set up, connected, tested, and handed over ready to operate.
Software and application training is possible at cnc-multitool, at your site, or online via TeamViewer.
Frequently asked questions
Which materials can I cut with the FW4000H?
The FW4000H processes PU, PUR, PIR, PE, EPP, XPS, as well as stone and glass wool.
Does the FW4000H fit in low-ceiling workshops?
Yes. With an operating height of 2.2 m it fits in workshops from 3,500 mm.
What is the difference between the FW4120H, FW4125H, and FW4130H?
The difference lies in the length of the machine table.
Which working widths are available?
The standard is 1,250 mm, with 2,000 or 2,500 mm additionally available.
Can I cut EPS (Styrofoam) on the FW4000H?
For EPS (Styrofoam) we recommend our hot-wire cutting machines – they are specialized in this material.
Can I cut blocks and boards?
Yes. The FW4000H processes blocks as well as boards positioned lying flat or standing upright.
Do blocks need to be fixed in place during cutting?
Heavy blocks usually do not. Light blocks must be fixed in place.
How are heavy blocks loaded onto the machine?
Most easily with a forklift.
Do boards need to be fixed in place during cutting?
Heavy boards usually do not. Light boards must be fixed in place.
How are upright boards stabilized?
With an optional vertical board stabilization.
Can I divide a block into several lengths?
Yes. Several cut-to-length cuts in succession can be performed.
Do I need CAM software?
For custom contours, yes. Simple cuts can be created via the machine plugin.
Am I tied to a specific CAD or CAM software?
No. Any suitable CAD or CAM system can be used.
What happens if there is a fault with the cutting wire?
The machine stops automatically.
Does the FW4000H need compressed air?
Yes. 6 bar of compressed air is required.
Do I need a dust extraction?
Yes. A suitable dust extraction is required.
Is a safety guard needed?
Yes. A suitable safety guard is required.
Can I test my own material before buying?
Yes. Sample cuts with your material are possible at our facility in Ilmenau.
Experience 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 experience the machine under real production conditions. You are also welcome to bring your own material and test it together with us.
In doing so, we can directly clarify which machine version, which cutting wire and which equipment make sense for your production.
Request a demo
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