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YOU CAN BUILD THE MACHINE THAT CUTS PERFECT AIRFOILS FOR THE PRICE OF A DEAD 3D PRINTER

A machine that cuts tapered, twisted aircraft wings in one pass, built from the electronics of a dead 3D printer.

by Michael Rechtin

FULL CAD BOM FIRMWARE DOCS

WorkshopRobotics

difficulty
●●●●○
time
a long weekend
license
none
repo
repo ACTIVE31 stars

WHAT YOU’LL NEED

  • 3D printer + filament — printable parts — files are in the repo
  • Electronic parts — full list with part numbers in the repo BOM
  • Dev board / microcontroller — runs the project firmware
  • Soldering kit + basic tools — one-time buy, serves every future build

Partner

Reach your Pi from anywhere — Remote desktop to the machine running this build — no port forwarding, works right from the browser.Try Getscreen.me
Videos
1

COMPAREE VERDICT

This is a proper four-axis CNC machine that cuts foam wings with taper and twist in a single drag, and the entire control stack is standard 3D printer electronics — Arduino Mega, RAMPS 1.4, TMC2209 drivers, NEMA 17 motors. The frame is 4040 aluminium extrusion with lead screws and V-wheels, the wire is tensioned by a spring lanyard to compensate for thermal expansion, and current delivery is through an ordinary MIG welding tip. It runs modified GRBL firmware and takes G-code generated from airfoil profiles. Commercially these machines start around 3,500 dollars and the large-format ones list at over 30,000, so the appeal is obvious. The catch is assembly documentation: there is a bill of materials and a YouTube build video, but no written step-by-step guide, and if you have never built a linear motion system before this will be hard. The bigger trap is licensing: the STL files are non-commercial, the GitHub repo has no licence at all, and the parametric CAD is paywalled on Patreon, which means modification is awkward and selling what you build — or what you cut with it — is not permitted. If you want a foam cutter for your own RC planes and you already have the 3D printer parts, this is a genuine path to a capable machine. If you want to start a small run of custom airfoils for sale, the licence stops you before you begin.

NOT IN THE REPO

  • —STL files for printed parts are on MakerWorld under Attribution-NonCommercial-ShareAlike 4.0, which permits personal builds but prohibits sale of the machine or anything cut with it.
  • —The GitHub repository has no licence file at all.
  • —Parametric CAD source files are Patreon-only and not included in the public release.
  • —This is version 2 from around 2024; version 1 from 2020 is a completely different design with different CAD and they cannot be mixed.
  • —Bill of materials is a text list in the repo with supplier links, not a structured spreadsheet.
  • —Assembly instructions are minimal: a few photos in the MakerWorld description and a YouTube build video, no written step-by-step guide.

Can I build this?

PrintPrinted mounts, brackets, wire guides and the tensioning spring anchor — roughly 15 parts total, print time around 30 hours depending on settings.
Buy4040 aluminium extrusion, 700mm and 400mm lead screws with anti-backlash nuts, V-wheels on eccentric nuts, Arduino Mega, RAMPS 1.4 board, TMC2209 stepper drivers, four NEMA 17 motors, 24V power supply for motors, separate variable DC supply for wire heating, nichrome or stainless steel wire, MIG welding tip, spring lanyard, assorted fasteners and limit switches.
Tools3D printer, hex keys, spanners, wire cutters, multimeter for tuning wire current, basic soldering for any wire connections not using screw terminals.
SkillsIntermediate: you need to assemble a linear motion system with lead screws and V-wheels, flash modified firmware to an Arduino, generate G-code from airfoil profiles, and tune wire temperature by measuring current. If you have built a 3D printer from a kit this is within reach; if you have not, expect a steep weekend.
TimeTwo full days if the parts arrive pre-cut and you have built something similar before; closer to four days if this is your first linear motion assembly and you need to troubleshload stepper tuning and wire tension.
Cost$$ — extrusion, lead screws and electronics together run 200-350 dollars depending on what you already own. The variable power supply for the wire is the single largest new purchase if you do not have one.
SafetyLow-voltage DC on the wire side (typically under 24V), but wire current can be several amps and the wire itself gets hot enough to cut foam, so do not touch it while powered. No mains voltage exposure if you use an off-the-shelf 24V supply. Standard workshop care around moving axes.

Build at your own risk. Projects involve tools, electronics and sometimes mains voltage — follow the creator’s safety notes.

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HeyGears G1: 10M+ colors and transparent parts in one print, plus UV printing on flat objects. Figures, parts and labels — no painting.

See how it prints

Videos

DIY CNC Hot Wire Foam Cutter V2

Build walkthrough and machine in operation, no voiceover, music only.

Gallery

Start here

Navigation into the creator’s own docs — we don’t rewrite the guide, we route you to the source.

  1. 1.Download the STL files from MakerWorld and read the licence terms (The licence is Attribution-NonCommercial-ShareAlike 4.0, which permits personal builds but prohibits commercial use of the machine or anything cut with it.)
  2. 2.Clone the GitHub repository for firmware and the bill of materials (The repo has no licence file. The BOM is a text list with supplier links.)
  3. 3.Watch the YouTube build video to see assembly sequence and wire tensioning (No voiceover, but you see the machine go together and the spring lanyard system in action.)
  4. 4.Order extrusion, lead screws, V-wheels and electronics from the BOM(Lead screw lengths are 700mm and 400mm; check the BOM for exact specs on anti-backlash nuts and V-wheel eccentrics.)

Resources

Documentation, files and community threads for this build — we link straight to the original sources and never rehost the creator’s files.

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See how it works

KNOWN ISSUES

  • This is version 2; the 2020 version 1 machine is a completely different design with different CAD and different firmware, and they cannot be mixed. Do not follow the old build video if you are using the new STLs.
  • The STL files are non-commercial and the GitHub repo has no licence at all, which means you cannot sell the machine or charge for wings cut with it. If you were planning a side business cutting custom airfoils, this licence stops you.
  • Parametric CAD source files are Patreon-only, so modifying the design to a different bed size or lead screw pitch means editing STLs or redrawing from scratch.
  • There is no written assembly guide — just a BOM, a few photos on MakerWorld, and a silent YouTube video. If you have never built a lead screw and V-wheel gantry before, expect to pause the video a lot.
  • Wire tensioning is critical: the spring lanyard has to keep the wire tight as it heats and expands, and if it is too loose or too tight the cut will wander. The video shows the mechanism but does not quantify spring rate or preload.
  • The variable DC supply for the wire is not in the standard 3D printer parts pile, and cheap ones with poor current regulation will give inconsistent cuts. Budget for a decent adjustable bench supply.

Can I use this to cut wings for sale?

No. The STL files are licensed Attribution-NonCommercial-ShareAlike 4.0, which explicitly prohibits commercial use. You can build it for yourself and cut your own RC plane wings, but you cannot sell the machine or charge for cutting services.

What is the difference between version 1 and version 2?

Version 1 was published in 2020 and is a completely different mechanical design with different CAD files. Version 2 is the current machine shown in the 2024 video. Do not mix parts or instructions between them.

Do I need the Patreon files to build this?

No for a stock build — the STLs on MakerWorld are complete. Yes if you want to modify bed size, lead screw pitch, or motor mounts, because the parametric CAD source is Patreon-only.

How hot does the wire get?

Hot enough to cut through expanded polystyrene foam in a single pass, which is around 200-300 degrees Celsius depending on wire gauge and current. The exact temperature depends on your DC supply settings and wire resistance.

Can I reuse electronics from a broken Ender 3 or Prusa?

Yes, if it has an Arduino Mega and RAMPS 1.4 or compatible board. Creality boards with different pinouts will need firmware changes. TMC2209 drivers are recommended but not strictly required; A4988 drivers will work with noisier steppers.

Community builds

No community builds yet — be the first, we feature the best ones.

Discussion1

FROM THE COMPAREE TEAM

Four axes cutting a twisted wing in one pass, and the electronics are off-the-shelf 3D printer parts. If you already have a dead printer in a cupboard, what would you cut first?

CompareeTEAM1h agoedited

Practical notes from our verification: the repository has no licence file while the STL files on MakerWorld are non-commercial, which is an awkward split and means the firmware is in legal limbo. The bill of materials is a plain text list with supplier links rather than a spreadsheet, and there is no written assembly guide — just a silent YouTube video and a few photos. The single biggest trap is that this is version 2; the 2020 version 1 machine is a completely different design with different CAD, and mixing them will waste a weekend before you notice. If you have built a linear motion system before, the video is enough. If you have not, expect to reverse-engineer a few details from the footage.

Michael Rechtin

Michael Rechtin builds CNC machines and RC aircraft tooling, and published this as version 2 of his foam cutter design around 2024. His framing of the cost is straightforward: if you already have a broken or old 3D printer lying around, you are halfway there.

GitHub

Star the project on GitHub

DISCLAIMER

  • Comparee is not the author of the projects featured here. All rights to each project belong to its creator — every page links to the original source, and we never host creators’ files.
  • Information is provided without warranty and may become outdated as projects evolve. Prices are indicative bands only — always check the creator’s parts list for current costs.
  • Building and operating any project is at your own responsibility. Protective equipment, safe workshop practice and compliance with local regulations are the builder’s responsibility.
GitHub repo