In response to numerous enquiries about cutting foam wing cores for the RCMW APR1 model, Mr D (the editor) has asked for an explanation of what's involved accompanied by pictures and diagrams. This is an aspect of aeromodelling often regarded as expensive and extremely complex. Nothing could be further from the truth, as hot wire foam cutting is both simple and cheap! Many commercially available wings are cut using high tech CNC machines, which provide excellent accuracy and repeatability. Along with this technology, comes a fairly high price tag to support the purchase of such machinery. I would guess that it is also a reasonably time consuming operation to set up for cutting a given aerofoil section. This cost is easily absorbed if a large volume production run is required, but to manufacture one-off wing sets has to be more expensive.
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