Build the exact handheld hot wire foam cutter shown in our step-by-step YouTube build gui This digital download contains the 3D printable bracket STL files (2-piece set) engineered specifically to clamp the entire assembly together cleanly and safely.

Watch the complete build and assembly tutorial on YouTube:  https://youtu.be/qc04TtqgKSE

Custom Design Features

• Perfect Hardware Fit: Custom recesses for 7x M3 countersunk screws and M3 stainless steel nuts.

• Power Module Housing: Internal slot tailored specifically for the Micro USB 5V Power Supply Module.

• Clean Wire Routing: Integrated internal channels for 0.5 sq mm double-core flexible copper wiring.

• Frame Compatibility: Molded to clamp securely around standard 5.4mm low-carbon steel mini hacksaw frames.

Required Bill of Materials (BoM) to Complete the Build

• Plastic Brackets: This STL download (Qty: 2 printed halves)

• Frame: 5.4 mm dia. mini hacksaw frame (low carbon steel)

• Cutting Wire: 32 Gauge Nichrome Wire (0.274mm dia. x 25 cm)

• Power Module: Micro USB Breadboard 5V Power Supply Module (Qty: 1)

• Fasteners: M3x25mm stainless steel countersunk screws (Qty: 7) & M3 stainless steel nuts (Qty: 7)

• Springs: 14mm spring steel tension springs with full loop center hooks (Qty: 2)

• Wiring: 0.5 sq mm flexible double-core PVC insulated copper wire (15 cm)

3D Printing Recommendations

• Material: PLA, PETG, or ABS

• Infill: 100% for optimal structural rigidity

• Supports: Minimal / Support-free orientation (flat face down)

Note: This is a digital STL file download only. No physical 3D printed parts or hardware will be shipped