Cutting Styrodur and XPS with Hot Wire
XPS is not the same as EPS. Cutting Styrodur with the same settings as Styrofoam produces poor results.
XPS Reacts Differently to EPS
Styrodur and XPS are extruded polystyrene panels - denser, more uniform and more stable than EPS Styrofoam. These very properties make XPS more demanding in hot wire cutting. The material reacts more sensitively to unstable wire conditions, conducts heat less well and is less forgiving of setting errors. Cutting XPS with the same settings as EPS almost always produces poor results.
Cutting Speed: Slower Than for EPS
The most important difference from EPS: XPS must be cut more slowly. While EPS can be cut at approx. 450-500 mm/min, for XPS we recommend approx. 350-400 mm/min. XPS dissipates heat less well than EPS - the wire needs more time to melt the material away cleanly. At too high a speed the wire briefly touches the material, catches and vibrates - waves occur.
Shorter Wire Length - Especially Important with XPS
With XPS the wire length is even more important than with EPS. The uniform material structure of XPS makes even small wire vibrations immediately visible as waves. A short wire vibrates considerably less than a long one - and therefore produces noticeably cleaner surfaces. Anyone who regularly cuts XPS should always choose the shortest possible wire length for their workpiece size.
The optimal cutting gap of approx. 2 mm is even more important with XPS than with EPS. If the gap is too small the wire touches the material - waves and grooves occur. If it is too large the surface becomes rough due to thermal damage. Make a short test cut, observe the gap and adjust the temperature until approx. 2 mm is reached.
Avoiding Waves on XPS Surfaces
Waves on XPS surfaces are the most common problem when cutting this material. The wire runs cleanly at first, then briefly catches and vibrates slightly - visible waves occur. Two measures almost always help: first, choose the wire length as short as possible; second, reduce the cutting speed to approx. 350-400 mm/min. In stubborn cases, also check the wire tension.
XPS vs. EPS - the Most Important Differences When Cutting
- Cutting speed: XPS approx. 350-400 mm/min, EPS approx. 450-500 mm/min
- Wire length: choose shorter for XPS than for EPS of the same block size
- Heat dissipation: XPS dissipates heat less well - more time needed to melt
- Surface sensitivity: XPS shows mistakes immediately - EPS is more forgiving
- Test cut: with XPS always make one before production
For clean XPS cuts: always choose the shortest possible wire length, reduce the cutting speed to approx. 350-400 mm/min, set the cutting gap to approx. 2 mm and make a short test cut before production. Together, these four measures almost always produce clean, wave-free surfaces.
Frequently Asked Questions
The key questions and answers on this topic.
How do you cut Styrodur with the hot wire?
Cut Styrodur and XPS more slowly than EPS - guideline approx. 350-400 mm/min. Choose the shortest possible wire length, set the cutting gap to approx. 2 mm and make a test cut before production.
Why do waves occur when cutting XPS?
Waves occur when the wire briefly catches on the material and then vibrates. With XPS this happens faster than with EPS because the material is more uniform and mistakes become visible immediately. Solution: shorter wire length and slower speed.
What is the correct cutting speed for XPS?
For XPS and Styrodur we recommend approx. 350-400 mm/min - considerably slower than EPS at 450-500 mm/min. XPS dissipates heat less well and needs more time for a clean cut.
Can I cut XPS with the same settings as EPS?
No. XPS needs a slower speed, a shorter wire length and more precise temperature setting than EPS. Anyone cutting XPS with EPS settings will almost always get poor surfaces.
Cutting XPS cleanly
We help you find the right setting for XPS and Styrodur - from our own production experience.
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