Chapter 1
IN THIS LESSON
How to: Hotwire Your Own Blanks using AkuShaper
💡 Recommended AkuShaper Plan: Up & Comer
Creating your own surfboard blanks using EPS foam is a great way to customize your shapes, save money, and work around the limitations of traditional blank availability. With AkuShaper’s full-size rocker profile printing feature, you can easily set up a blank-cutting system at home. Here’s a step-by-step guide to getting started.
Why Use AkuShaper for Custom Blanks?
Precision: AkuShaper ensures accurate rocker curves for a perfect blank foundation.
Flexibility: Customize blanks to match your exact surfboard design specifications.
Cost Savings: Reduce material waste and maximize large EPS blocks by cutting multiple blanks.
Accessibility: Great for shapers without easy access to traditional pre-shaped blanks.
For a full walkthrough of the hot wire process, check out this detailed video from Dzjie Foils, where they cut an EPS blank from start to finish: Video above
Step 1: Print a Full-Size Rocker Profile in AkuShaper
AkuShaper makes it simple to generate an accurate rocker profile for your blank. Follow these steps:
Open AkuShaper and load your surfboard design.
Navigate to File > Print and select Full-Size Rocker Profile.
Print the profile to scale on multiple sheets (tape them together if needed) or use a large-format printer for a single seamless print.
Cut out the printed profile to create a precise template.
Rocker Profile View
File -> Print Menu
Full size rocker print preview
Step 2: Build a Hot Wire Cutter
A hot wire cutter is an essential tool for shaping EPS foam blanks. If you don’t have one, you can build a simple version using nichrome wire and a power source. Here are some useful resources:
How to Build a Hot Wire Cutter: https://www.instructables.com/Hot-wire-foam-cutter/
DIY Hot Wire Power Supply: https://www.instructables.com/Hot-Wire-Cutter-Battery-Power-Supply/
Key tips for using a hot wire cutter:
Use nichrome wire (not standard metal wire) for consistent heat.
Maintain steady, even tension while cutting.
Work in a well-ventilated area, as EPS fumes can be harmful.
Step 3: Cut the Blank Using Your Rocker Profile
Once your rocker profile is printed and your hot wire cutter is set up, it’s time to shape your blank:
Secure the printed rocker profile to a thin piece of plywood or MDF and cut out a sturdy template.
Mark the EPS foam block with guide lines to ensure proper alignment.
Run the hot wire cutter along the template, following the rocker curve smoothly and steadily.
Refine the blank by cutting the outline and adjusting thickness as needed.
PRO TIP
“I like to use three rocker profiles—one in the center as the ‘stringer’ and two on the sides. It’s the safest way to start. You reduce the chance of user error or issues from a slack hot wire. Even if the wire sags a little, the middle guide keeps your cut true. Once you’ve dialed in your setup and skills, you can skip the center stringer—like when making a stringerless board—but for beginners, this method adds an extra layer of insurance.” - Geert Groenewegen, Dzjie Foils
Using multiple rocker templates gives your cut added stability and helps maintain accuracy, especially on longer boards or when your wire isn’t perfectly tensioned. It's a simple move that can seriously improve your results.
Industry-Grade CNC Hot Wire Machines
For shapers looking for a more automated and scalable approach, industry-grade CNC hot wire machines are available. Companies like KM System offer advanced shaping machines that use precision-controlled hot wire technology to cut EPS blanks with high accuracy and efficiency. These machines are ideal for:
High-volume blank production
Complex rocker and outline designs
Reducing material waste and human error
You can learn more about hot wire shaping machines here: https://kmsystem.fr/wordpress/shaping-machines/
Final Tips & Resources
Best Practices for Gluing Stringers in EPS Blanks: [External Video]
Sanding and Prepping Your Blank for Shaping: [Polyola Blanks Blog Link]
By leveraging AkuShaper’s tools and a simple hot wire setup, you can efficiently create custom blanks tailored to your designs. Ready to get started? Open AkuShaper and start printing your rocker profiles today!
🔧 What's Next?
Ready to try it yourself?
Use AkuShaper to print a full-size rocker template and start shaping your own blanks at home.
Sign up for AkuShaper here: https://www.akushaper.com/users/new
Not sure which blank to match to your design?
Browse our built-in Blank Library or load in your own EPS dimensions for an accurate cut.
Curious about stringers?
Check out our next guide: How to Make and Glue In Your Own Stringers →
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Have your own hotwire setup or tips?
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