Short Wires Win

Wire lengths that are too long reduce cut quality, accuracy and speed. Why shorter is almost always better in hot wire cutting – and when long wires still make sense.

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Cutting Styrofoam

How to cut Styrofoam and EPS cleanly with a CNC hot wire – speed, temperature and wire length guidelines from real production.

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Cutting Styrodur

Styrodur and XPS react differently to EPS – and therefore need different settings. What really matters in hot wire cutting of XPS.

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Variable Wire Length

Variable wire lengths allow short stable cuts in daily use and long wire lengths when needed – all on one machine. How it works and when it makes sense.

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Wire Length for EPS

Which wire length is optimal for EPS standard blocks – and why shorter is almost always better. Practical knowledge for the right machine selection.

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Wire Length for XPS

Which wire length is optimal for XPS and Styrodur – and why shorter wires are even more important with XPS than with EPS.

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Cutting Speed

How cutting speed and wire temperature are related – and how to achieve the optimal cutting gap of approx. 2 mm in CNC hot wire cutting.

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Wire Temperature

How wire temperature is set practically at the material in hot wire cutting – explained step by step with guidelines for EPS, XPS and EPP.

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Avoid Waves

Why waves appear on cut surfaces in hot wire cutting – and how to prevent them through correct wire length and cutting speed.

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Poor Surfaces

Rough surfaces, grooves and uneven cut edges in hot wire cutting – identify causes and resolve them permanently.

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Wire Gets Stuck

Why the hot wire gets stuck or breaks in CNC hot wire cutting – and what to do about it. Identify causes and prevent wire breakage.

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Single Wire vs. Multi-Wire

When is a single-wire machine better – and when does a multi-wire machine pay off? The decision depends on production, not on the machine.

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2 Axes vs. 4 Axes

What is the difference between 2-axis and 4-axis cuts in hot wire cutting – and when do I really need 4 axes?

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Rotation Really Needed?

A rotation table is needed far less often in practice than customers assume. When it makes sense – and when to leave it out.

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When Does Multi-Wire Pay Off?

Multi-wire machines significantly increase production output – but only when the production is really suited for it. When multi-wire makes sense.

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Which Machine Is Right?

Systematic decision guide for the right CNC hot wire machine – from production analysis to machine recommendation.

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Large Machines – A Mistake?

Bigger is not better in CNC hot wire cutting. Why oversized machines deliver worse quality and cost more.

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Cutting Neopor

Neopor is EPS with graphite content – and presents special challenges in hot wire cutting. What to consider and which machines are suitable.

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Production Before Machine

Those who plan production first and then buy the machine make better decisions. Why production planning matters more than machine selection.

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Hot Wire and Routing

Hot wire and router complement each other perfectly – hot wire for rough contours, router for details. When and how to combine both.

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Monolithic Cutting

In monolithic cutting there are no visible entry marks. How it works and when it makes sense.

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Material Handling

How large EPS blocks are moved safely and efficiently to the hot wire machine – loading concepts and practical tips.

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