Custom Foam Cutting Capabilities

We custom cut wing cores for electric, glow, gas and rocket powered R/C models, gliders and a variety of UAS.

Aircraft Types:

We have produced wing cores for many different types of R/C aircraft from Giant Scale Flying Boxcars to Park Flyers.  Our capabilities include, but are not limited to:

  • Giant Scale Aerobatic Aircraft
  • Pylon racers
  • Ducted Fan and Turbine Powered Jets
  • Sport Flyers
  • Electric and Park Flyers
  • Slope Racers
  • Thermal Gliders
  • Slope Combat Aircraft (See our kits!)
  • RPV’s and UAV’s

We also have cut blades for windmills and wind tunnel fans.

Wing Shapes:

Since our process uses a hot wire, we are limited to ruled surfaces, or surfaces that are defined by 2 cross sections, where a straight line exists between a point on one cross section and the corresponding point on the 2nd cross-section.

In the case of a wing panel, airfoil shapes define the cross-sections.  See the Airfoil section below for more information on the available airfoils in our library.  Our process allows the 2 airfoil cross-sections to be sized differently, forming a tapered wing panel, or they can be the same, forming a constant chord wing panel.

We can easily cut washout into a panel and allow for sheeting thickness of zero up to 1/4″.

We cannot cut elliptical wings.

Airfoil Selection:

We have several hundred airfoil profiles to choose from.  We also can generate NACA 4,5, and 6 digit airfoils.  We can cut any airfoil that has been designed or modified in Compufoil, Profili, or stored in Compufoil (.cor) file format.

Our Airfoil library consists of:

  • Airfoil profiles that exist on various web sites on the Internet.
  • Airfoils that we have created. Most of these are flat bottom airfoils, or fully symmetrical airfoils used on Giant Scale Aerobatic Aircraft.


Wing Tube, Joiner Rod, or Wing Rods:

We can accurately cut round holes for Wing Tubes, also known as Wing Joiner Rods or Wing Rods.  These holes are cut by one of two methods.  Most Giant Scale aircraft use a Wing Tube hole that terminates in a rectangular slot.  The slot is used for bow access and is typically finished by glueing in a wooden wing tube support plate, and a tube stop plate.  The wing tube sleeves protrudes slightly through the support plate, and is later sanded flush with the wing core so that becomes bonded with the wing skin during the covering process.  This plate prevents the end of the wing tube sleeve from working its way loose in the foam after many flights.  The stop plate is glued to the outside surface of the rectangular slot and prevents the wing tube from penetrating the foam core when the wing is installed on the aircraft.

If a blind wing tube hole is required, we can cut the core at the end of the sleeve before cutting the tube hole.  The cores can be glued together prior to sheeting to form a core with a blind hole.

In either case, the tube holes are cut with a hot wire, using the circular interpolation of the OpenCNC control system.  The tube holes are very accurate and can be sized for a close fit to any sleeve diameter.  Less glue is needed to install the tube sleeve in the core resulting in a light, strong wing.

Vertical & Horizontal Stabilizers:

We also cut both Verticle and Horizontal Stabilizers for the variety of aircraft listed above.

Fuselage Cores:

We do a limited number of Fuselage parts that lend themselves to hot wire cutting.  Most fuselages consist of compound curves that cannot easily be cut with a hot wire.  We do some hatch covers and turtle deck pieces that are defined by 2 profiles.  We are not capable of doing fuselages that are defined by multiple cross-sections.

Volume Orders:

We cut cores for a number of kit and ARF manufacturers.  We have processed orders for up to 500 sets of cores at a time.  We welcome volume orders and will compete favorably with other foam cutters’ pricing.