CNC Foam Cutting Machine ScuptoFoam

Mohammed Jaddou; Amjad Mousa

CNC Foam Cutting Machine ScuptoFoam

dc.contributor.author	Mohammed Jaddou
dc.contributor.author	Amjad Mousa
dc.date.accessioned	2026-02-03T08:48:58Z
dc.date.available	2026-02-03T08:48:58Z
dc.date.issued	2025
dc.description.abstract	Cutting foam for packaging, insulation, and prototyping requires precision and efficiency, but traditional approaches such as manual cutting or bulky industrial CNC machines present significant challenges. Manual cutting often lacks accuracy and consistency, while existing CNC systems are expensive, power-hungry, and typically dependent on a laptop or external computer for operation. This project addresses these limitations by introducing a portable and standalone CNC foam cutting machine that combines affordability, usability, and flexibility for both 2D and 3D cutting applications. The proposed system integrates electronics, software, and mechanical components into a compact unit. An Arduino Uno controls three stepper motors, each corresponding to the X, Y, and Z axes, while a DC-DC converter regulates current to a heated wire used as the cutting tool. A Raspberry Pi with an attached monitor replaces the traditional PC interface, allowing direct standalone operation. In addition, a Flask-based mobile/web application provides remote control over Wi-Fi, enabling users to jog the machine, upload G-code files, and monitor cutting progress in real time. Key hardware elements include three NEMA stepper motors, a heated wire with adjustable temperature control, a DC-DC converter, and a custom-built frame. On the software side, a desktop GUI on the Raspberry Pi handles G-code visualization and manual controls, while the Flask server delivers a responsive and mobile-friendly interface. Together, these systems enable precise and automated cutting of foam into 2D shapes and 3D structures without the need for external computers. Despite challenges such as limited availability of components, fragility of 3D-printed couplers, and ensuring reliable serial communication between the Raspberry Pi and Arduino, the prototype was successfully built and tested. Results demonstrate accurate and efficient cutting, confirming the machine’s potential as an educational and prototyping tool. The modular and scalable design of this CNC foam cutter opens the door for future enhancements, such as extending compatibility to plastics, Integrate camera/vision system for monitoring, Automated material handling. This project demonstrates how embedded systems and automation can be applied to create cost-effective and standalone manufacturing solutions, bridging the gap between DIY approaches and industrial CNC equipment.
dc.identifier.uri	https://hdl.handle.net/20.500.11888/20806
dc.supervisor	Dr.Hanal Abu-Zant
dc.title	CNC Foam Cutting Machine ScuptoFoam