Resistance Hot Cutting Wire - Knight Group

Hot Cutting Wire

Efficient and Precise Hot Cutting Wire Solutions for Manufacturers

Hot cutting wire is essential for the precise cutting of complex shapes from polystyrene foam (EPS) and extruded polystyrene (XPS). These wires are made from special nickel alloys or stainless steel and are heated to approximately 200°C by electrical resistance. As specialist manufacturers, the Knight Group provides free quotations on your wire and cable requirements.

Hot Cutting Wire: Efficient and Precise Cutting Wire Solutions for Manufacturers

Resistance wire is used as a hot cutting wire for the accurate cutting of complex shapes from polystyrene foam (EPS) and extruded polystyrene (XPS).  The wire is typically made of a special nickel alloy or stainless steel and is heated to approximately 200°C by electrical resistance. This innovative solution offers numerous benefits to manufacturers and industries requiring accurate cutting and shaping of materials.

Hot wire cutting is used extensively in the packaging industry and for cutting shapes for R&D prototyping, modelling and architectural mouldings.

Over the years, Hot Cutting Wire technology has evolved with advancements in material development, leading to improved performance and efficiency. Knight Group has been at the forefront of this innovation, providing high-quality resistance wires that cater to the diverse needs of manufacturers across industries.  

Take advantage of our expertise in Hot Cutting Wire solutions.

Our cutting-edge technology and top-of-the-line equipment allow us to produce wire solutions that are not only durable but also incredibly precise, ensuring that you can get the exact cut you need every time.  As specialist manufacturers of Wire and Cable, we can provide free quotations on your requirements.  Contact Knight Group today for a free quotation on your requirements and discover how our cutting-edge technology can elevate your manufacturing processes.

Physical Properties of Hot Cutting Wire

MaterialPhysical & Service Properties
ORW - LGood heating characteristics and easily bent to shape for hand cutting of patterns.
ORW - MModerate strength and low electrical resistivity are utilised for low heat applications.
ORW - HGood heating characteristics in a medium strength wire.
ORW - EHHigh strength at elevated temperature, with good creep resistance. The best general purpose cutting wire.
ORW - SThe highest specification cutting wire. Very high strength at elevated temperatures, with high creep resistance.
MaterialResistivity µΩ/cmDensity g/cm³Strength N/mm²Max. Op. Temp.°CCoefficient of Expansion µm/m°C
ORW - L1088.35800115017.5
ORW - M708120095017.6
ORW - H1228.28130070012.6
ORW - EH1188.18140095012.7
ORW - S1318.25160098013.6

What are the benefits hot cutting wire?

Accurate and clean cutting of complex shapes from EPS and XPS materials

Widely applicable in the packaging industry, R&D prototyping, modelling, and architectural mouldings

Reduced waste due to precise cutting and minimal material loss formability, allowing for the creation of intricate shapes and components

Energy-efficient as the wire is heated only by electrical resistance

Adaptable to various applications with the use of different alloys and wire materials

Comprehensive FAQ Guide for Hot Cutting Wire

Hot cutting wire is a versatile and essential tool in various industries, from packaging to architectural moldings. Understanding its properties and applications is crucial for professionals in industries that rely on accurate cutting results.  To help you better understand this cutting-edge technology, we have compiled a list of the top 10 most frequently asked questions about hot cutting wire.  

We hope this comprehensive FAQ guide will answer all your questions about hot cutting wire. If you require further assistance or would like to place an order, you can use our contact form01707 645261 or 

Hot cutting wire is typically made from special nickel alloys or stainless steel. These materials provide excellent resistance and heat-conducting properties, allowing the wire to reach high temperatures for efficient cutting while maintaining its structural integrity.

Hot cutting wire works by heating the wire through electrical resistance. As the wire heats up, it melts the material it comes into contact with, allowing for precise and clean cuts. The temperature of the wire can be adjusted depending on the material being cut and the desired cutting speed.

Hot cutting wire is primarily used for cutting polystyrene foam (EPS) and extruded polystyrene (XPS). However, it can also be used for cutting other foam materials, such as polyurethane foam and polyethylene foam, depending on the wire’s temperature and cutting speed.

Hot cutting wire is widely used in various industries, including packaging, research and development prototyping, modeling, architectural moldings, and insulation.

There are several types of hot cutting wire systems, including handheld cutters, table-mounted systems, and CNC-controlled machines. The choice of system depends on the specific application, required precision, and production volume.

When using hot cutting wire, it is essential to wear protective gloves and safety goggles to protect your hands and eyes from potential burns and debris. Additionally, ensure your workspace is well-ventilated to avoid inhaling harmful fumes, and keep a fire extinguisher nearby in case of emergencies.

The temperature and cutting speed of hot cutting wire can be adjusted using the power supply or hot wire cutter controls. Refer to the manufacturer’s instructions for specific guidance on temperature and speed settings for different materials and desired cutting results.

After each use, allow the hot cutting wire to cool down completely before handling it. Clean the wire with a damp cloth to remove any residue or debris. Store the hot cutting wire in a safe and dry location, away from moisture and extreme temperatures.

If the hot cutting wire is not heating up, check the power supply and connections to ensure they are functioning properly. If the wire is bending or breaking during use, reduce the pressure applied and ensure the wire is properly secured.

You can purchase high-quality hot cutting wire from Knight Precision Wire. Knight Precision Wire, a division of the Knight Group, is a specialist manufacturer of wire and cable. We offer free quotations on your requirements and can provide expert advice on selecting the ideal hot cutting wire solution for you.

Knight Precision Wire are specialist wire and cable manufacturers and can provide free quotations on your requirements. You can use our contact form01707 645261 or

All data is provided for informational purposes only. In no event will the Knight Group and its subsidiaries, be liable for in respect of any action taken by any third party arising from using the information taken from our online or printed sources. Chemical and Mechanical Properties should not be construed as maximum or minimum values for specifications, nor should information be used to assess suitability for a particular use or application. The information and data provided is deemed to be accurate to the best of our knowledge and may be revised anytime without notice and assume no duty to update