Produce drones, wings and EPS wing cores

EPS wing cores for light and precise wings

EPS is light, readily available and precise to process with hot wire. Typical are EPS wing cores for drones, UAVs, gliders and other aerodynamic applications.

The cut EPS wing core forms the aerodynamic base shape. Depending on the build-up, the core can then be sheeted with balsa wood or reinforced and laminated with fiberglass or carbon fibre.

EPP wings for robust and elastic applications

EPP is elastic and impact-resistant and is particularly suitable for robust wings and heavily stressed drone or model-flight parts.

EPP is available in white and black. Depending on the material type, the density is around 20 to 60 kg/m³. In model making, around 20 kg/m³ is often used. Panels are available up to approx. 1800 × 1200 × 150 mm.

For hot wire cutting we recommend white EPP. Black EPP contains graphite and therefore has less favourable cutting properties.

EPP wings are often additionally reinforced with fabric tape. For higher bending and torsional stiffness, carbon fibre or fiberglass spars can also be integrated into the wing.

EPP too can be cut precisely with CNC hot wire into tapered, swept or twisted wings and wing cores.

There are wings with a continuously identical contour. In this case both sides of the cutting wire trace the same geometry – a parallel cut results.

There are also wings with a different left and right contour. For this, four CNC axes are needed: each side of the machine traces its own profile. In this way, for example, different root and tip profiles can be joined in one cut.

In addition, wings can be designed tapered and twisted. Here the profile size, angle and course change over the span. This is exactly where the 4-axis cut plays to its strengths.

Why is the wire length important?
The longer the wire between the two cutting units, the more it limits the possible angle between the left and right contour. With strongly twisted wings, a wire that is too long can therefore restrict the geometry. An adjustable or variable wire length makes it possible to adapt the wire to the respective wing geometry and thus to cut larger amounts of washout.

Open control with G-code

The machine control processes G-code. This lets you freely combine different CAM programs and CAD software – from profile and wing design to the generation of the cutting paths.

Our in-house styroCAM Draht software is also available, but is not a requirement. You keep the choice of your software and your familiar workflow.

From the profile to the wing core

Wing profiles can be imported as profile data and assigned to a root and tip profile. For the 4-axis cut, both sides are synchronised so that tapered and twisted wings are created in one continuous cut.

In this way both individual prototypes and recurring parts can be produced reproducibly.

Smaller wing cores and precise drone parts?

For smaller and medium wing cores as well as precise drone and UAV parts from EPS and EPP panels, the CUT1610SV is particularly suitable.

Thanks to the variable machine table and the adjustable wire length, the CUT1610SV is particularly suitable for washout cuts, as the wire length can be set to match the geometry.

Large wing cores and strong washout?

For larger wings, long parts and industrial applications, the CUT3000S series is the right solution. Four independently controlled CNC axes enable tapered and twisted wings over large working areas.

Optionally, the CUT3000S can be equipped with an automatic wire tensioner. The cutting wire is sensor-controlled wound and unwound and automatically kept under tension. This makes strong washout possible even with large parts and long wire lengths. 45° washout is no problem.

Mill parts or cut them with the knife?

The W2 series complements hot wire processing for parts and materials that are not produced with the wire.

With the oscillating knife, light sheet materials such as balsa wood can be cut precisely, for example. With the milling spindle, firmer materials such as carbon fibre, fiberglass or plywood can be processed.

Mold making is also possible. From materials such as XPS, models, master patterns, negative molds or other three-dimensional parts can be milled.

Both methods can also be combined: first, for example, recesses, pockets or other areas are milled, then the outer contour is cut with the knife – in one operation and without moving the part to another machine.

Wing cores and flying wings

Parallel, tapered, swept and twisted wing cores can be cut with CNC hot wire directly from EPS or EPP panels.

With 4-axis cuts, different profiles at root and tip can be joined in one continuous cut.

Fuselages and fuselage segments

Fuselages, fuselage segments and aerodynamic foam cores can be produced from EPS or EPP depending on the geometry.

Simple contours can be cut with hot wire. More complex 3D geometries can be milled on the W2 series.

Nacelles and aerodynamic fairings

Motor, sensor or landing-gear fairings as well as other aerodynamic parts can also be produced with hot wire or milling.

The processing method depends on the material, part shape and desired surface geometry.

Structural parts from sheet material

Formers, ribs, reinforcements and other structural parts can be produced on the W2 series from suitable sheet materials.

Balsa wood can be cut with the oscillating knife. Plywood, carbon fibre and fiberglass are processed with the milling spindle.

Models and mold making

For development, prototyping and mold making, three-dimensional geometries can also be milled from materials such as XPS on the W2 series.

Possible are, among others, models, master patterns, negative molds and other parts for the development and manufacture of drone and UAV components.