Sign Making with CNC Hot Wire - 3D Letters and Logos from EPS
From graphic file to finished 3D letter in a few steps - with Corel Draw, styroCAM and CNC hot wire.
EPS Is the Ideal Material for 3D Sign Making
EPS Styrofoam is the most widely used material for 3D letters, logos and display lettering. It is light, easy to coat, cost-effective and can be cut precisely with the hot wire. Sign makers who use CNC hot wire cutting can produce individual 3D lettering in a short time - without expensive milling times, without much dust, without complicated setup.
The Workflow: From Corel Draw to the Finished Part
Step 1: create or import the logo or lettering in Corel Draw. Convert text to curves - styroCAM cannot read fonts, only geometries. Step 2: export as DXF - unit millimetres, check for closed contours. Step 3: import the DXF into styroCAM, define the monolithic cutting path, generate G-code. Step 4: pre-drill the EPS block, thread the wire, cut monolithically - no visible entry mark. Step 5: coat, paint or laminate the part.
The most important trick for clean 3D letters: monolithic cutting. In a normal cut the wire enters the block from the outside and leaves a visible entry mark - a small line that still shows through after coating. In a monolithic cut the block is pre-drilled, the wire is threaded and the contour is cut as a fully closed path. No entry point, no visible seam. The result looks professional.
Corel Draw Tips for the Hot Wire
- Always convert text to curves (Ctrl+Q) before exporting DXF
- Check all contours for gaps - closed must mean closed
- Export DXF in millimetres - not in centimetres or inches
- Convert splines to lines where possible
- Simplify details that are too fine - the hot wire has a cutting gap of approx. 2 mm
- Font sizes under 5 cm are difficult - observe the minimum letter height
Which Machine for Sign Making?
For sign making all 4-axis single-wire machines from cnc-multitool are suitable. The CUT1600S is ideal for smaller logos and letters up to 1250 mm. The CUT2000S and CUT3000S for larger lettering and signs. All machines support monolithic cutting - the prerequisite for professional 3D sign making.
Frequently Asked Questions
The key questions and answers on this topic.
Can I export directly from Corel Draw for the hot wire?
Yes. First convert text to curves (Ctrl+Q), then export as DXF in millimetres. styroCAM imports the DXF file and generates the cutting path.
What is monolithic cutting and why is it important for sign making?
In monolithic cutting the block is pre-drilled, the wire is threaded and the contour is cut as a fully closed path - without a visible entry mark. For professional 3D letters and logos this is indispensable.
What minimum size do letters cut with the hot wire have?
As a guideline, a minimum letter height of approx. 5 cm applies. Smaller letters are difficult because the cutting gap of approx. 2 mm becomes too large in relation to the letter size.
3D Sign Making with Hot Wire
We show how the complete workflow from the graphic file to the finished 3D letter works.
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