For industrial series production of pipe insulation shells, insulation components and contour-cut parts – including the processing of complete pallets of boards without unloading them.
Do you want to produce recurring contours in series while reducing material handling? The FW5000H Series is a CNC fastwire contour cutting machine for industrial series production. It processes large material formats and supports repeatable cutting operations in everyday production.
Depending on the material, you can process individual blocks, flat boards or complete pallets of stacked boards directly on the machine table. With suitable material and pallet dimensions, the boards remain on their pallet during processing: there is no need to unload, position and restack each board separately.
The fast-running cutting wire can produce pipe insulation shells, insulation profiles, insulation components, protective packaging, technical cut parts and individual 2D contours from stone wool, various foams and other insulation materials.
The machine uses a fast-running cutting wire that separates the material mechanically without heat input. The endless wire reaches speeds of almost 300 km/h.
The FW5000H is designed for recurring cutting tasks and high quantities – while keeping additional material handling to a minimum.
The FW5000H processes blocks, flat boards and complete pallets of boards. Saved cutting programs support the repeatable production of pipe insulation shells, insulation elements and technical contour-cut parts.
Material blocks can be loaded by forklift or via a roller conveyor. With pallets of boards in particular, there is no need to load each board separately: the complete pallet is processed directly on the machine table.
Individual 2D contours can be prepared and reused for recurring orders. This keeps production flexible even when larger quantities are required regularly.
With the FW5000H you can produce pipe insulation shells, insulation elements, protective packaging and series parts from blocks, boards or complete pallets of boards.
Pipe shells and insulation shells for pipework and industrial insulation – manufactured repeatably in series.
Insulation profiles, insulation elements and technical cut parts for construction, plant engineering and industrial applications.
Contour-cut protective parts for large or sensitive components – manufactured to match their geometry.
Cut recurring contours directly from complete pallets of boards – for high quantities with as little additional material handling as possible.
The FW5000H processes PU, PUR, PIR, stone wool and other suitable foam and insulation materials – in blocks or flat boards.
Large material blocks are processed directly on the open machine table. This produces, for example, pipe insulation shells, insulation profiles, insulation elements and individual 2D contours.
The FW5000H processes stone wool, foams and other suitable board materials lying flat. Suitable pallets of boards can be processed directly on the machine table without unloading individual boards. For cutting upright boards, the FW4000H Series with vertical board stabilisation is intended.
Depending on how your material is supplied, the FW5000H processes it as a block, a board or directly as a complete pallet.
For EPS and expanded polystyrene, we recommend our hot-wire cutting machines.
Material blocks made from PU, PUR and PIR are picked up alongside the machine and moved onto the open table – directly from a forklift or via a roller conveyor. They are then aligned and cut under CNC control.
This produces pipe insulation shells, insulation profiles, insulation elements, technical cut parts and free-form 2D contours.
Heavy blocks usually remain securely in place under their own weight.
Raw material can be cut to length and trimmed to defined dimensions beforehand.
Stone wool, foams and other board materials are processed exclusively lying flat on the machine table.
This enables insulation elements, technical cut parts and individual contours to be produced from boards.
If you want to cut boards upright – for example, several identical contours in one operation – the FW4000H Series with vertical board stabilisation is the appropriate machine.
Boards are frequently delivered as complete pallets. The pallet is placed directly onto the open machine table with a forklift.
The boards can remain on the pallet and are processed using the prepared cutting program. This eliminates the need to unload boards individually. The possible pallet height and contours in one cutting sequence depend on the material, dimensions and cutting task.
The four models differ only in the length of the working area. Width, working height, axes, cutting wire and electrical requirements are the same for all models. The decisive factor in choosing a model is therefore the length of your material.
The FW5120H and FW5125H are designed for common standard blocks measuring 2,000 and 2,500 mm, the FW5130H for 3,000 mm and the FW5140S for material up to 4,000 mm. Larger dimensions are available on request.
Cutting speed depends on material, density, cutting thickness, contour and cutting wire.
The achievable cutting speed depends on material type and density, cutting height, contour and the cutting wire used. A single thin board requires less material to be cut through than a large block or several stacked boards on a pallet. Feed rates for these applications therefore cannot be compared directly or specified as a general value.
For a reliable assessment of processing time and cutting quality, we are happy to carry out test cuts with your material and the intended cutting height in our sample production facility.
The FW5000H uses a fast-running abrasive endless wire for mechanical contour cutting without heat input.
The FW5000H works on the principle of a CNC wire saw using a fast-running abrasive cutting wire. It cuts the material mechanically without heat input.
The cutting wire consists of several core wires around which another wire is wound. Different windings are used depending on the material to achieve the best possible cutting quality and speed.
The cutting wire has a diameter of 1.2 to 1.6 mm. Wire type and feed rate are matched to the material. The cutting wire is a consumable; its service life depends in particular on the material, its density and the quantity cut, and cannot be specified as a general figure.
Load the program, position the material and start cutting – the FW5000H carries out the programmed cutting sequence under CNC control.
The operator loads the prepared cutting program, positions blocks, flat boards or a pallet of boards on the machine table and starts processing. The FW5000H performs the programmed contour cut repeatably.
We provide documents and videos to help with familiarisation. Software and application training is available at cnc-multitool, at your premises or online.
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 everyday production.
CAM software converts a CAD drawing (DXF or DWG) into a machine program. Prepared contours can be saved and reused for recurring series production orders. CAD, CAM and machine software are separate; you can use any suitable CAM software. Our own styroCAM Fastwire is included for the first year.
For simple cuts – such as straight cuts, rectangular contours, cut-outs or mitres – a plugin is available directly on the machine. The operator enters dimensions and movements without preparing a CAD drawing or CAM program. Because we develop the software in-house, customer-specific functions are also possible.
cnc-multitool provides support in the event of faults by telephone, email or remote service – and on site if required.
If service is required, you receive support directly from cnc-multitool by telephone, email or remote access, so many questions can be resolved immediately.
Important components are easily accessible and can be replaced quickly; if necessary, a service technician visits your site. The aim is always to keep downtime as short as possible.
The FW5000H Series is designed for reliable everyday production: a stable steel construction, powerful wire drive and practical operating and safety systems.
The machine frame and worktable are made of welded and painted steel profiles. The robust design ensures smooth running and repeatable cutting results.
The open machine table is easily accessible: blocks and boards can be loaded, aligned and removed easily – a complete pallet is placed directly on the table using a forklift.
The circulating cutting wire is driven by a powerful 4 kW three-phase motor. Even high-density materials can be cut without the wire losing speed under load.
The wire speed is controlled directly via the machine software and adjusted to the material being processed.
The cutting wire is tensioned pneumatically during operation. 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 path, the machine stops automatically. After inspection or wire replacement, the program continues from the stop position.
Abrasive cutting generates dust that must be extracted. The cutting arms are enclosed and equipped with two 100 mm extraction connections.
An extraction unit offered by us or a suitable external extraction system can be used.
Together with the machine software and controller, the computer system forms the FW5000H operating environment. It is supplied ready for operation with a current Windows Pro licence – computer, interfaces and software are matched to one another.
All cnc-multitool computer systems include a second SSD as a backup drive.
The operator console is located directly on the FW5000H and is dust-protected for the production environment. Computer, monitor, keyboard, mouse and operating controls are arranged at one fixed workstation.
This gives the operator the machine, software and production documents exactly where they are needed – with the cutting process controlled from the workstation at the machine.
The most important technical data of the four machine models in direct comparison. The full specifications are provided in the technical data sheet for each model.
The FW5000H Series is delivered as a CNC fastwire contour cutting machine prepared for commissioning. The machine, controller and essential software are already included.
Suitable extraction and safety equipment are required for operation.
Depending on the material and cutting wire, abrasive wire cutting produces sawdust. Suitable extraction is therefore required for production operation.
An appropriate extraction system can be purchased from us or provided by the customer.
A suitably integrated extraction system can be switched on and off via the machine software.
Suitable safety equipment is required to operate the machine.
Depending on the installation and production environment, this may comprise a safety fence and safety light curtains.
The safety equipment can be ordered from us or supplied by the customer in accordance with applicable safety regulations.
The FW5000H can generally be commissioned by the customer; support and on-site installation are available.
You can generally commission the FW5000H yourself – we provide documentation and videos and offer remote support if needed.
On request, our technicians carry out installation and commissioning at your premises – assembling, connecting and checking the machine before handing it over ready for operation.
Software and application training is available at cnc-multitool, at your premises or online via TeamViewer.
Answers about the FW5000H – from materials, models and pallet processing to software, equipment and service.
The FW5000H is particularly suitable for PU, PUR, PIR, stone wool and other foams.
The difference is the length of the machine table.
The standard working width is 1,250 mm. Optional widths of 2,000 mm or 2,500 mm are available.
Yes. The FW5000H is designed for processing material blocks.
The easiest way is by forklift or roller conveyor.
Yes, for individual contours. Simple cuts can be created using the machine plugin.
No. Any suitable CAM software can be used.
The machine stops automatically.
Yes. Compressed air at 6 bar is required.
Yes. Suitable extraction is required for production operation.
Yes. Suitable safety equipment is required.
Yes. Test cuts using your material are possible at our facility in Ilmenau.
Yes. Complete pallets of flat boards can be placed on the machine table and cut without unloading the boards.
No. The FW5000H processes boards exclusively lying flat. The FW4000H Series with vertical board stabilisation is intended for upright boards.
For EPS, we recommend our hot-wire cutting machines.
Would you like to see how different foams and insulation materials can be processed on the FW5000H?
Visit us in Ilmenau and see the machine under real production conditions. You are welcome to bring your own material and test it with us.
We can then determine directly which machine version, cutting wire and equipment make sense for your production.
Request demonstrationComplement your FW5000H Series with suitable machines and accessories for your production.
Multi-wire panel cutting machine for cutting panels.
CNC Fastwire machine for cutting boards and small blocks.
CNC Fastwire machine for cutting blocks and boards – even in low halls.
CNC Fastwire roof cutting machine for tapered insulation and roof elements.
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