FW4000H Series
Flexibly cut large foam and insulation blocks
Precise contour cuts for industrial production — with a machine operating height of just 2.2 m.
optional 2,000 / 2,500 mm
Flexible processing of large foam and insulation blocks
With the FW4000H you produce pipe insulation sections, insulation components, profiles and contour-cut parts directly from large material blocks — flexibly, from one-off orders to recurring series production. This CNC contour cutting machine for block materials processes PU, PUR and PIR in particular, as well as stone wool boards and other foams and insulation materials. With an operating height of just 2.2 m, it is also suitable for production halls with a ceiling height of 3,500 mm or more.
The blocks can be used to make pipe sections, insulation profiles, insulation elements, custom contours and boards to the required thickness. Saved cutting programs enable repeatable cuts for customer orders and series production.
The FW4000H processes boards flat or, with the vertical board stabilizer, in an upright position, allowing several identical contours to be cut in a single operation.
The FW4000H uses an abrasive cutting process: a fast-running endless wire cuts the material mechanically, without heat, and reaches speeds of nearly 300 km/h.
For boards and small blocks, our FW1000H Series is the appropriate choice.
What production tasks can it handle?
The FW4000H is a production machine for large material blocks, suitable for individual customer orders and series production of recurring components.
Produce contour-cut parts directly from blocks
Instead of buying pre-cut material, you process suitable production blocks in-house. This allows you to make pipe insulation sections, insulation profiles and other technical contour-cut parts to drawing, with flexible dimensions and contours.
Handle customer orders flexibly
Individual orders and different contours can be prepared as needed. Where the material and cutting sequence allow it, several parts can be cut from the same block to make efficient use of the available material.
Produce recurring components in series
Saved cutting programs can be reused for new orders. This ensures repeatable production of consistent contours and allows frequently required components to be manufactured in advance.
What can I produce?
With the FW4000H, you produce pipe insulation sections, insulation elements, transport protection and boards to the required thickness directly from large blocks.
Pipe insulation sections
Pipe insulation sections made from PU, PUR and PIR for pipe and plant insulation — produced in series directly from blocks.
Insulation elements
Insulation elements and contour-cut parts from large blocks for construction, plant engineering and technical applications.
Transport protection
Large, contour-cut protective parts for bulky components — for example, wind turbine rotor blades.
Which materials can I process?
The FW4000H Series processes foam and insulation materials in the form of boards or blocks.
Blocks
PU, PUR and PIR are often processed as block materials. Common standard blocks are approximately 2,000 or 2,500 mm long.
Blocks can be used to produce pipe insulation sections, insulation profiles, insulation elements, individual contours or boards to the required thickness.
Boards
PE, EPP, XPS and stone wool are mainly processed as board materials.
Boards can be cut flat or upright on the FW4000H.
Other suitable foam and insulation materials can also be processed.
How can I produce parts?
The FW4000H Series supports different processing methods depending on the component, material and production task.
For production involving mainly EPS (expanded polystyrene), our CNC hot-wire cutting machines are the specialized solution.
Cutting blocks
Heavy material blocks are easy to handle. Their own weight keeps them securely on the machine table during cutting, so additional clamping is not normally required.
An optional fork-tine opening in the machine table allows direct loading by forklift.
Cutting boards
Boards can be cut flat or upright.
Heavy boards remain securely on the machine table under their own weight during cutting and do not require additional fixing.
Upright boards must also be stabilized to prevent sideways tipping. A vertical board stabilizer is available for this purpose.
Several upright boards can be positioned side by side and cut with the same contour 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 the required block lengths produced.
Several cuts to length can also be performed in succession, dividing a longer block into sections with defined lengths.
Trimming removes irregular or unwanted outer areas, providing clean reference surfaces for subsequent processing.
Which machine should I choose?
The appropriate FW4000H model depends primarily on the length of your material blocks and components.
The difference between the FW4120H, FW4125H, FW4130H and FW4140H is the length of the machine table. The FW4120H handles material up to 2,000 mm, the FW4125H standard blocks up to 2,500 mm, the FW4130H material up to 3,000 mm and the FW4140H material up to 4,000 mm.
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 be kept as small as possible. Increasing the working width can reduce cutting quality and achievable feed rate. We therefore recommend selecting a width that matches the material formats actually required.
How fast can I cut?
Cutting speed depends on the material, material density, contour, material thickness and cutting wire.
The material determines the cutting speed
The achievable cutting speed depends on the material, density, contour and cutting wire and cannot be stated as a single general value.
No reliable universal cutting speeds can be given for the different block materials. For meaningful figures, we can carry out test cuts with your material in our sample production facility.
Which cutting wire is used?
The FW4000H cuts with a fast-running abrasive cutting wire — mechanically, without a thermal cutting process.
The FW4000H uses a fast-running cutting wire that cuts the material mechanically, without introducing heat.
The cutting wire consists of several wire cores with an additional wire wound around them. Different windings are used depending on the material to achieve the best possible cutting quality and speed.
The cutting wire typically has a diameter of 1.3 to 1.6 mm. Wire type, wire speed and feed rate are matched to the material. The cutting wire is a consumable; its service life depends particularly on the material, material density and volume cut.
How easy is it to operate?
Load the cutting program, place and align the material, start the cut — the machine performs the programmed cutting sequence.
The operator loads the prepared cutting file, positions the material block or boards on the machine table and starts the cut. The FW4000H then carries out the programmed movements automatically and repeatably.
Operating instructions are provided for familiarization. If required, software or application training is available at cnc-multitool, at your site or online.
Which software is used?
CAD, CAM and machine software are separate on the FW4000H. You can continue to use existing suitable systems or use our solutions, making job preparation straightforward for one-off orders and recurring contours.
CAM software for custom contours
CAM software converts a CAD drawing (DXF or DWG) into a machine program that is loaded and executed on the machine.
CAD, CAM and machine software are separate, so you can use any suitable CAM software. Our own styroCAM Kaltdraht is included for the first year.
Machine plugin for simple cuts
For simple cuts — straight cuts, rectangular contours, cut-outs or mitres — a plugin is available directly on the machine, without CAD or CAM.
The operator enters dimensions and movements directly; the machine follows the path and then stops automatically.
What happens if service is needed?
If service is required, cnc-multitool provides direct support by telephone, email or remote support, and an on-site service technician when needed.
You receive support directly from cnc-multitool. Many faults and questions can first be assessed together by telephone, email or remote support and can often be resolved immediately.
Important FW4000H components are easily accessible and can be replaced quickly if necessary. Many tasks can also be performed by your own employees after consulting our service team. If an on-site repair is required, a service technician will carry it out. The aim is always to keep downtime as short as possible.
Machine features
The FW4000H Series is designed for reliable daily production. Its features include a sturdy steel structure, a powerful wire drive and operating and safety systems tailored to production requirements.
Sturdy steel structure
The FW4000H Series is built from welded and painted steel profiles. Its heavy-duty construction ensures smooth machine operation and forms the basis for repeatable cutting results. Its low operating height of 2,200 mm allows installation in halls with a ceiling height of 3,500 mm or more.
The open machine table remains easily accessible: material blocks and boards can be positioned, aligned and removed easily — heavy blocks can be handled by forklift, for example.
Powerful cutting-wire motor
The endless cutting wire is driven by a particularly powerful 4 kW three-phase motor. Even high-density materials can be cut without the wire losing speed or becoming stuck under load.
Wire speed is controlled directly through the machine software and adjusted to the material.
Pneumatic wire tensioning with automatic stop on wire breakage
The cutting wire is tensioned pneumatically during operation. Constant tension prevents sagging and vibration — essential for clean, smooth cut surfaces without grooves.
If the wire is damaged or an unexpected event occurs along its path, the machine stops automatically. After inspection or wire replacement, the program resumes at the stop position.
Enclosed cutting arms for dust protection
Abrasive cutting generates dust depending on the material, which must be extracted. The cutting arms are enclosed and equipped with two 100 mm dust-extraction connections.
A dust extractor supplied by us or another suitable external extraction system may be used.
Control PC package
Together with the machine software and controller, the computer system forms the FW4000H operating environment. It is supplied ready for operation with a current Windows Pro licence; computer, interfaces and software are matched to each other.
All cnc-multitool computer systems include a second SSD as a backup drive.
Dust-protected operator console directly on the machine
The operator console is mounted directly on the FW4000H and protected against dust for the production environment. Computer, monitor, keyboard, mouse and controls are arranged at a fixed workstation.
This gives the operator direct access to the machine, software and production documents at the point of use, allowing the cutting process to be controlled from the machine workstation.
Technical data
The key technical data for the four machine variants in direct comparison.
Scope of delivery
The FW4000H Series is supplied as a CNC contour cutting machine prepared for commissioning. The machine, controller and essential software are already included.
Included:
- FW4000H CNC contour cutting machine
- Machine controller
- Control PC package
- Machine software
- Machine plugin
- styroCAM Kaltdraht (first year included)
- Dust-protected operator console
- 12-month warranty
Required equipment
For production operation, the FW4000H requires suitable dust extraction and an appropriate safety system.
Dust extraction
Abrasive contour cutting produces sawdust depending on the material and cutting wire. Suitable dust extraction is therefore required for production.
An appropriate extraction system can be purchased from us or provided by the customer.
A suitably connected extraction system can be switched on and off via the machine software.
Safety system
An appropriate safety system is required to operate the machine.
Depending on the installation and production environment, it may consist of safety fencing and safety light curtains.
The safety system can be ordered from us or supplied by the customer in accordance with applicable safety regulations.
Options and accessories
With suitable optional equipment, the FW4000H can be adapted for block handling, board processing and material fixation.
Forklift loading
Heavy material blocks are easiest to position on the machine using a forklift.
The machine table can be equipped with an integrated opening for the forklift tines. The block is placed directly onto the table and then positioned accurately, simplifying material handling and reducing manual loading work.
Vertical board stabilizer
Boards cut in an upright position must be stabilized against sideways tipping. For this purpose, the FW4000H can be equipped with a vertical board stabilizer whose side support panels are adjusted to the material thickness.
The stabilizer is removable and is used only when required for the particular processing task.
Vacuum table
Very light blocks or boards can be moved by the cutting wire and therefore require additional fixing. The FW4000H Series can be equipped with a vacuum table that holds the material securely on the machine table during cutting.
This largely eliminates the need for additional mechanical fixings.
Material hold-down
For material that cannot be reliably held by its own weight or by the vacuum table, the FW4000H Series can be equipped with a material hold-down.
Two rollers press the material onto the machine table during cutting and hold it in position. This also allows light or difficult-to-secure blocks and boards to be processed reliably.
Installation and commissioning
You can generally commission the FW4000H yourself; on request, our technicians can carry out installation at your site.
The FW4000H Series can generally be commissioned by the customer. Once the machine has been positioned and aligned, the controller and computer are connected and the machine is started up. We provide documents and videos for these steps and remote support if required.
On request, our technicians carry out installation and commissioning at your site and hand over the machine ready for operation after connection and inspection.
Software and application training is available at cnc-multitool, at your site or online via TeamViewer.
Frequently asked questions
Key answers about the FW4000H — from materials and models to operation, equipment and service.
Which materials can I cut with the FW4000H?
The FW4000H processes PU, PUR, PIR, PE, EPP, XPS and stone wool.
Can the FW4000H be installed in low-ceilinged halls?
Yes. With an operating height of 2.2 m, it fits in halls with a ceiling height of 3,500 mm or more.
What is the difference between the FW4120H, FW4125H, FW4130H and FW4140H?
The difference is the length of the machine table.
Which working widths are available?
The standard width is 1,250 mm; widths of 2,000 or 2,500 mm are also available.
Can I cut EPS (expanded polystyrene) on the FW4000H?
For EPS (expanded polystyrene), we recommend our CNC hot-wire cutting machines, which are designed specifically for this material.
Can I cut both blocks and boards?
Yes. The FW4000H processes blocks and boards positioned flat or upright.
Do blocks need to be secured during cutting?
Heavy blocks generally do not. Light blocks must be secured.
How are heavy blocks loaded onto the machine?
The easiest way is with a forklift.
Do boards need to be secured during cutting?
Heavy boards generally do not. Light boards must be secured.
How are upright boards stabilized?
With an optional vertical board stabilizer.
Can I divide one block into several lengths?
Yes. Several cuts to length can be made one after another.
Do I need CAM software?
Yes, for individual contours. Simple cuts can be created using the machine plugin.
Am I tied to a particular CAD or CAM program?
No. Any suitable CAD or CAM system can be used.
What happens if there is a problem with the cutting wire?
The machine stops automatically.
Does the FW4000H need compressed air?
Yes. A compressed-air supply of 6 bar is required.
Do I need dust extraction?
Yes. Suitable dust extraction is required.
Is a safety system required?
Yes. An appropriate safety system is required.
Can I test my own material before purchasing?
Yes. Test cuts using your material can be carried out 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 welcome to bring your own material and test it with us.
We can then determine which machine version, cutting wire and equipment are appropriate for your production.
Request a demonstrationOther interesting products and accessories
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