Precision Foam Cutting for Wings and Tail Surfaces

With the molds prepped and ready for layup, we moved on to the important task of cutting the wings and tail surfaces. These components were cut from EPS foam using a 4-axis CNC hotwire cutter. This technique enabled us to produce precise, lightweight parts with clean, smooth cuts that maintained the necessary aerodynamic profiles. In addition, using a 4-axis CNC hotwire cutter eased the refinement and reshaping process as the development of the surfaces progressed. Once each piece was correctly cut, the foam components were prepared for the carbon fiber layups and eventual incorporation into the overall aircraft design. Overall, this was a crucial step in advancing us toward the final stages of assembly.

Key Achievements:

• Used EPS foam and a hotwire cutter for precise cutting of wings and tail surfaces.
• Minimized foam weight while ensuring aerodynamic integrity.
• Prepared foam components for further refinement and shaping in the build process.