Foam Needle Cutter

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Posts: 61
Joined: Fri May 11, 2012 2:14 pm
Location: East Coast Iowa

Foam Needle Cutter

Post by Mudshark » Tue Apr 16, 2019 2:17 am

I have added a foam needle cutter to the tools I use on my Shapeoko platform. I build custom fishing rods and will make eva foam handles with inlays. To do this, you need to make cuts with little to no kerf. Getting precision fits can be difficult due to the small detail size.

Billy Vivona is the craftsman that I look up to for his amazing skills making fishing rod handles that he learned from studying marquetry. You can find his work on facebook and

I came across djk4linux posts on forum that detail his needle cutter design work. I took his build and adapted it to fit my shapeoko. Some leftover 1/2" polycarbonite and some makerslide for the frame. I printed his flywheel and needle guide designs from thingiverse and have been very happy with the results. Electronics and RC motor from ebay, mig tip needle guide from Harbor Freight and piano wire from Hobby Lobby.

I mostly cut 1-2mm eva foam and construction paper while using a 1/4" foam board as a waste board. Materials for the build were sourced from ebay, Hobby Lobby and product materials from Michaels.
Side view of cutter
01d9e7be43bc23e0fe49c2cb468bf063044be81c0d.jpg (544.63 KiB) Viewed 293 times
Close up of flywheel, cutter and guides
0196ed3ddee15960be7a895c82d2b972d61b72dae6.jpg (438.18 KiB) Viewed 293 times
Needle guide
01c505a0ed06b4489c763c076f95376eaacc247db5.jpg (351.14 KiB) Viewed 293 times
Serial #0054, 2 Watt laser, dual X motors, double Y, ACME Z Axis, G540, Mach 3, rotating axis, needle cutter, Proxxon, 750mm x 375mm, laser cross hairs, auto zero, GT2
Ordbot #201, E3d hot end, bourdon tube feeder.

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