Many customers compare machines by their maximum travel speed. In hot wire cutting this is largely irrelevant. Machine travel speed describes the idle movement without cutting – in hot wire cutting there are hardly any idle movements. What really matters is cutting speed: how fast the hot wire moves through the material. And this is not determined by motor power but by the material and the wire temperature.
A hot cutting wire thermally melts material away in front of it. Ideally the wire never touches the material directly – it melts it at a distance. When a constant cutting gap of approx. 2 mm forms, the cut runs optimally: clean surfaces, sharp edges, high dimensional accuracy. If the cutting gap is too small, the wire touches the material – poor surfaces and dimensional deviations result. If it is too large, accuracy is lost.
Cutting speed is not calculated theoretically but set practically at the material. Procedure: first set the cutting speed – use the guideline values from the table as a starting point. Then make a test cut and observe the cutting gap. If the gap is smaller than 2 mm, increase wire temperature. If it is larger than 2 mm, reduce temperature. Repeat until the cutting gap is consistently approx. 2 mm. Material can react differently depending on density and manufacturer – so always set practically, never prescribe theoretically.
Wire temperature is set via the power supply. Power supplies have two controls: one for voltage (volts) and one for current (amperes). Our recommendation: turn voltage fully open and set the current control to approx. 2.3–2.4 A as a starting value. Then make a test cut and measure the cutting gap. If the gap is smaller than 2 mm, increase amperes slightly. If it is larger than 2 mm, reduce amperes slightly. Adjust until a consistent cutting gap of approx. 2 mm is achieved. The exact ampere value depends on the material, wire length and wire used – the starting value of 2.3–2.4 A is a proven guideline.
XPS and Styrodur react fundamentally differently to heat than EPS Styrofoam. The material dissipates heat less well and reacts more sensitively to unstable wire conditions. At too high a cutting speed the wire briefly touches the material, catches slightly and releases again – visible waves form. With approx. 350–400 mm/min and the right cutting gap, XPS can be cut precisely and cleanly.
In hot wire cutting the wire cuts continuously – there are hardly any idle movements between cuts. Maximum machine travel speed therefore plays almost no role in practice. Anyone comparing machines by this value is comparing the wrong thing.
Mains voltage fluctuations can change wire temperature and affect cut quality. The automatic current controller compensates for these fluctuations via microprocessor control. It automatically adapts to wire length and material and keeps temperature constant. The result: consistent cut quality throughout the entire production day – regardless of mains fluctuations.
Always set cutting speed first – then adjust temperature via the ampere control. Never the other way round. Temperature is the adjustment dial for the cutting gap, speed determines productivity. Both must be coordinated with each other. And: always set at the real material – guideline values are reference points, not a substitute for the test cut.
EPS and Styrofoam can be cut at approx. 450–500 mm/min. This is a guideline – the optimal speed can vary depending on density and wire length. Always set practically at the material and observe the cutting gap.
XPS and Styrodur can be cut at approx. 350–400 mm/min. XPS reacts differently to heat than EPS and must be cut slower to avoid waves. The guideline values apply at a wire length up to approx. 1250 mm – adjust accordingly for longer wires.
XPS and Styrodur react differently to heat than EPS. The material dissipates heat less well and reacts more sensitively to unstable wire conditions. At too high a speed waves form. Guideline for XPS: approx. 350–400 mm/min.
The ideal cutting gap is approx. 2 mm. The wire melts the material away in front without touching it directly. If the gap is smaller than 2 mm, increase temperature. If it is larger, reduce temperature.
Power supplies have two controls: voltage and current. Turn voltage fully open, set current to approx. 2.3–2.4 A as a starting value. Make a test cut and check the cutting gap: gap smaller than 2 mm – increase amperes. Gap larger than 2 mm – reduce amperes. Adjust until a consistent cutting gap of approx. 2 mm is achieved.
With higher density material, increase temperature – do not reduce speed. The goal always remains the 2 mm cutting gap. Increase amperes slightly until the cutting gap is approx. 2 mm again.
No. In hot wire cutting there are hardly any idle movements – the wire cuts continuously. Maximum machine travel speed plays almost no role in practice. What matters is wire length, machine quality and software.
The automatic current controller compensates for mains voltage fluctuations via microprocessor control and keeps wire temperature constant. This ensures consistent cut quality throughout the entire production day – regardless of mains fluctuations.
We help with the correct settings for your machine – from real production experience, not from the manual.
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