What is the disadvantage of cutting expanded polystyrene with a hot wire cutter?

Answer 1

I would think, considerable unless proper safety equipment was worn, ie glasses, breathing mask, etc. Polystyrene is a plastic and like most plastics, when you burn it, it releases chemical vapors. These things are dangerous if breathed in. Either don't do it (also bad for the enviroment), or do it in a well ventilated place. First answer's warnings notwithstanding, as it turns out, if you properly adjust the temperature on the wire, it will only melt the foam and will not cause dangerous quantities of noxious vapors from the products of thermal decomposition. Just because you can make the wire glow red doesn't mean you have to. Practice on scrap in a well ventilated area until you hit on the proper setting and speed of cut. You'll know if it is too hot because black sooty smoke will be produced--that's bad. One more thing: don't do this in the same room where you have your paint, thinners, acetone, and other stuff that goes BOOM. The wires break and sparks ignite.

Answer 2

none