Short Wires Win
Many customers want maximum flexibility and therefore initially choose the largest machines with the longest wire lengths. Understandable – after all,...
Practical Knowledge
Optimal Wire Length for Cutting XPS and Styrodur
With XPS wire length is even more critical than with EPS - short wires are the decisive factor for clean surfaces.
XPS Does Not Tolerate Long Wires
With EPS slight wire vibrations can often still be tolerated - the material is forgiving. With XPS and Styrodur it is different. The uniform dense structure of XPS makes even the smallest wire vibrations immediately visible as waves on the surface. Anyone wanting to cut XPS cleanly must pay particular attention to short wire lengths.
XPS Panels - Typical Dimensions
- Thickness: typically 60 mm to 200 mm
- Width: typically 600 mm to 1250 mm
- Length: typically 1250 mm to 2500 mm
- For standard panels up to 1250 mm wide: 1250 mm wire length is sufficient
- For wider panels: adjust wire length accordingly
Why Short Wire Length Is So Important for XPS
XPS has a very uniform, dense material structure - much more uniform than EPS Styrofoam. This property makes XPS valuable as insulation material - and demanding to cut. Every wire vibration immediately leaves visible marks on the surface. A short wire vibrates considerably less than a long one. With XPS, wire length alone can determine whether surfaces are good or poor.
Recommendation: Shortest Possible Wire Length for XPS
For XPS cuts even more than for EPS: always choose the shortest possible wire length. For XPS standard panels up to 1250 mm wide, a wire length of 1250 mm is perfectly sufficient. Anyone cutting wider panels should choose the wire length accordingly - but never unnecessarily long. Combined with the right cutting speed of approx. 350-400 mm/min and the optimal cutting gap of 2 mm, excellent results can be achieved with this setting.
First Determine Wire Length - Then Choose the Machine
The right sequence: first determine the required wire length - as short as possible for daily production - then choose the right machine. Almost all machines in the cnc-multitool range are available in different wire lengths. Only the CUT1600S has a fixed wire length. For XPS we recommend the CUT1600S, CUT2000S or CUT2500S - or if needed a CUT3000S with 1250 mm wire length.
Frequently Asked Questions
The key questions and answers on this topic.
Show questions
Which wire length do I need for XPS panels?
For XPS standard panels up to 1250 mm wide, a wire length of 1250 mm is perfectly sufficient. For wider panels, adjust accordingly. Always choose the shortest possible wire length.
Why do waves appear so easily with XPS?
XPS has a very uniform dense material structure that makes even the smallest wire vibrations immediately visible as waves. Short wire length and slower cutting speed (350-400 mm/min) help the most.
Which machine is recommended for XPS?
For XPS we recommend CUT1600S, CUT2000S or CUT2500S - or if needed a CUT3000S with 1250 mm wire length. What matters is not machine size but the right, shortest possible wire length. First determine the wire length needed, then choose the machine.
Find the Right Machine for XPS
We help with selecting the right machine and wire length for your XPS production.
Related Knowledge
Related articles from our practical knowledge on this topic.
Wire Length for EPS
The right wire length for EPS is determined by daily production – not by the largest possible cut. Getting this wrong means buying an unnecessarily large machine.
Variable Wire Length
With most hot wire machines wire length is fixed. Variable wire length means: this distance is adjustable – short for precision, long for large formats.
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