It has been suggested to me that the RC'ers here on Openbuilds might be interested in my Brushed/Brushless Motor Foam Cutter. The method is "novel/unique" but not new... I've been using it for several years now to cut all kinds of planes and figures out of various sheet foams (bluecor, DTF, etc). I actually introduced this back on the Phlatforum (http://www.phlatforum.com/xenforo/threads/perforator-style-foam-cutting-head.2836/) in the summer of 2012 as a possible attachment for the Phlatprinter Mk3 -- Mark even thought it was neat! -- but sadly it never gained tracion or much notice. But recently it has undergone further development/refinement on my thread over on the RCPowers forum (Mostly Printed CNC and cutting foam) and been adapted to Ryan "allted" Zellars' Mostly Printed CNC (Mostly Printed CNC / MultiTool by Allted). This is a very flexible and affordable CNC machine in its own right... I've built 3 of then over the past 2 months for myself and a couple of friends. The foam cutter attachment itself however is simple/cheap, relatively easy to build (3d printed parts are NOT necessary), and easily adapted to virtually any CNC machine. I have published a couple of versions the CNC foam cutter attachment on Thingiverse. There is a brushed DC motor version (MPCNC foam-cutter attachment by dkj4linux) and an 2826/2822 brushless motor version (MPCNC 2826 Brushless RC Motor Foam Cutter by dkj4linux). It is absolutely perfect for cutting sheet foams for RC aircraft parts. I've been using this method for several years now to machine-cut my planes out of fanfold foam insulation sheet and DollarTree foamboard. And though it appears crude I have cleanly cut many sheets of foam using this method with minimal fuss. Basically, it's a very fast reciprocating needle... like a sewing machine. The needle is formed from a length of 0.025" music-wire and attached to a small ball-bearing mounted eccentrically on the flywheel. The flywheel is mounted on the shaft of a 2826 brushless motor (with ESC and servo tester) and spun at 8000-10000 rpm, resulting in a stroke/perforation per revolution. A feed rate of 600-1000 mm/min yields 10-15 strokes/mm and cleanly cuts DollarTree foam board (paper on), blue-cor fanfold foam, etc. WRT the tool chain I use, I most often convert PDF plans (or whatever) to DXF and import into SketchUp, scale/edit/arrange the parts into one or more sheets, and then use the SketchUCAM plugins to generate gcode. Straight-pin a sheet of foam board onto the bed of the CNC, load the plane/figure gcode, set the origin, and let it rip. Twenty minutes or so later you have a sheet of parts that are accurately cut, easily punched/pressed out, and hot-glued together. Please take a look. I'll offer information and support to help as best I can if you decide to give it a try.