Foam Needle Cutter

Mudshark · 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 northeastrodbuilders.com.

I came across djk4linux posts on flitetest.com 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 203 times

: Close up of flywheel, cutter and guides; 0196ed3ddee15960be7a895c82d2b972d61b72dae6.jpg (438.18 KiB) Viewed 203 times

: Needle guide; 01c505a0ed06b4489c763c076f95376eaacc247db5.jpg (351.14 KiB) Viewed 203 times