Design · Analysis · CAD · Software
4-Axis Foam Cutting Machine
Designed and built a 4-axis CNC foam cutting machine for rapid fabrication of aerodynamic components used in SAE and VTOL projects.
Precision
±0.5 mm
Cutting accuracy for aerodynamic foam components
Efficiency
~50%
Reduction in prototyping time vs manual cutting
Application
SAE & VTOL
Used for vehicle bodies and wing development
Project Overview
This project involved the design and construction of a custom 4-axis CNC hot-wire foam cutting machine intended for rapid fabrication of aerodynamic components. The system was primarily developed to manufacture wing sections and fuselage profiles for SAE competition vehicles and personal VTOL aircraft projects, while remaining flexible enough for broader prototyping applications. The machine enables synchronized motion across four axes, allowing complex tapered geometries to be cut accurately and repeatably from foam stock.
Problem Definition
Aerodynamic prototyping for student competition teams typically relies on manual hot-wire cutting or outsourced CNC services, both of which introduce limitations. Manual methods lack repeatability and precision, while commercial multi-axis CNC foam cutters are cost-prohibitive and inaccessible for student teams. The challenge was to create a low-cost, in-house manufacturing solution capable of producing accurate airfoil and fuselage geometries without sacrificing flexibility, precision, or iteration speed.
Design & Analysis
The machine was designed from scratch in CAD, including the structural frame, axis layout, bearing mounts, and hot-wire carriage system. Components were modeled in Fusion 360 with attention to rigidity, alignment, and synchronized four-axis motion, achieving ±0.5 mm cutting accuracy.
Software & Toolchain Integration
Aerodynamic geometry generation was handled using specialized foam-cutting software. Open aerodynamic design tools were used for basic airfoil definition and analysis, while DevWing Foam and DevFus Foam (proprietary software) were employed for generating advanced wing and fuselage geometries with precise root-to-tip transitions. Generated toolpaths were exported as G-code and executed through GRBL-based machine control, enabling real-time control of the hot-wire cutter and synchronized multi-axis motion.
Manufacturing & Assembly
To keep the system accessible and cost-effective, the majority of custom components were 3D printed, including structural mounts, bearing housings, and alignment fixtures. Standard aluminum extrusion and laser-cut plates were used where higher stiffness was required. This hybrid manufacturing approach enabled rapid iteration: parts could be redesigned in CAD, printed, and installed within hours, allowing mechanical issues to be resolved quickly during development.
Results & Outcome
The completed machine successfully produced repeatable, high-quality foam components for aerodynamic testing and competition use. Wing cores and fuselage sections were manufactured for SAE vehicles and VTOL projects, significantly improving surface consistency compared to manual methods. Overall, the system reduced prototyping time by approximately 50%, enabled faster design iteration, and provided a reliable in-house manufacturing capability for complex aerodynamic geometries.
Skills Demonstrated
- • CNC machine design & assembly
- • Fusion 360 CAD
- • DevWing / DevFus workflows
- • GRBL & G-code execution
- • 3D printing for functional parts
- • Rapid prototyping