Hi all! I've been trying to come up with a way to cut foam sheets for some of my drone projects. I had to balance temperature and speed. I may have thought of something that was discovered years ago but I still find it postworthy. I just setup my hotwire cutter on and angle. It gave me a nice smooth cut without jittermarks. The speed is set by the angle of the board. I set the temperature by adjusting the width of the leads. For a power source i'm using an old lipo battery charger. Here are some results of just test foam.
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Cool idea. Are you only able to cut straight lines or have you been able to make any wings as well?