Engineer or not..........I need your help

[doggie750]

I need to enhanced/ redesign the hot wire FOAM cutting mechanism to be more functional in polymer (solid gel, high density material) manufacturing. Preferably a handheld device when cutting the polymer gel.

My initial design would be similar to the hacksaw, will utilize the frame and replace the blade with 3 hot wires (high heat life wire:) parallel in 2 or 3. Due to adhesion factor after the initial cut, secondary/ third wire will reinforce the heat and separate the material. IMO, secondary wires should be thicker than the initial wire to be more effective.

NOTE:
Tensioner for all wires.
The cutting wire is made of High life Inconel X750 wire (up to 2 year life on a single wire). This type wire is designed for long life and high heat strength. This type of wire also allows for less stress from heat fluctuations and stretch over the life of the wire.

Power source: 12V or more with current regulator to adjust heat dissipation.
PICS attached:

NOW, I NEED YOUR BRAINs to help me out.

THANKS.

[TNRabbit]

Check R/C airplane forums for details on what you're looking for; they use these for cutting foam wings all the time.