Cutting wires
Reliable in use
Cutting wires for industry and trade
Our cutting wires ensure clean, precise cuts in a wide range of applications – from foam processing to model making to aerospace engineering. Whether soft or high-density materials, small batches or industrial production: We supply cutting wires tailored to your application.
Thanks to high-quality materials, modern manufacturing technologies, and a wide range of designs, our cutting wires offer excellent cutting performance with a long service life. They are equally suitable for manual and automatic cutting systems and meet the highest requirements for dimensional accuracy, tensile strength, and processing quality – even in demanding applications in continuous industrial operation.
Cutting wire versions
Our cutting wires are available in various spiral designs, diameters, and lengths – depending on the material, cutting quality, and application:
Smooth cutting wire (single-wound spiral)
Standard design for precise, clean cuts in soft to medium-hard foams.
Double-wound cutting wire
Offers greater stability and longer service life – ideal for denser or firmer foams.
Coarse spiral structure
Enables fast cuts with low friction – perfect for industrial applications.
Fine spiral structure
For maximum precision in delicate cuts – especially in model making or the medical field.
High-strength cutting wires made of special alloy
Extremely wear-resistant and tensile strength – developed for high-performance applications in the automotive and aerospace industries.
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Available cutting wires:
Versatile areas of application
Our cutting wires are used in numerous industries and materials:
Upholstered furniture and mattress production
Precise cuts for foam cores and upholstery.
Packaging and protective padding production
Production of individually shaped cushions for delicate products.
Architecture and model making
Detailed shape cuts for architectural models and prototypes.
Industry and custom-made products
Application in the production of technical foam parts.
Automotive industry
Manufacture of sound insulation, seat upholstery and cladding elements.
Stage and exhibition construction
Designing decorative elements, stage sets and displays.
Sports and leisure industry
Cutting of foams for sports mats, protective equipment and fitness equipment.
Medical technology
Manufacture of orthopedic insoles, positioning aids and padding materials.
Aerospace industry
Custom-made vibration-damping and insulating foams.
Technical data & availability
Available diameters: 1.1 mm / 1.3 mm / 1.5 mm / 1.6 mm
Tensile strength: 1000 – 1600 N/mm²
Lengths: 3,500 mm to 12,900 mm
All cutting wires are also available in custom lengths or customized versions – precisely tailored to your cutting system and the desired application.
HaBuR cutting wires – For perfect cuts from start to finish. Request cutting wires in your desired length now.
FAQ – Quick Guide
How does a cutting wire cut foam materials?
With the spiral cutting wires offered here, the cutting action is created by the movement and structured surface of the wire. The wire is guided through the material by the cutting system and separates it along the specified cutting path. This allows both straight cuts and more complex contours to be produced. The achievable cut quality depends on factors such as the wire design, the material, its density and the machine settings. The cutting wire and the equipment must therefore be matched to the specific cutting process.
Which cutting wire is suitable for which material?
The appropriate wire design depends primarily on the type, density and abrasiveness of the material. Flexible PU foam places different demands on the cutting wire than PE foam, rebond foam or rigid PU foam. Fibrous and more abrasive materials such as fibreglass or rock wool also require suitably designed wires. Certain versions can also be used for cutting cardboard blocks. The material designation alone is therefore not sufficient. Material density, required surface quality, machine type and production speed should also be considered when selecting the wire.
Why are the spiral structure and winding pattern of a cutting wire important?
The spiral structure and winding pattern determine how the cutting wire engages with the material and transports removed particles away from the cutting area. Finer structures are generally more suitable for controlled cuts and precise contours. Coarser or more robust designs may be required for denser, harder or more abrasive materials. A more aggressive structure can increase material removal, but may also affect dust formation and the resulting cut surface. The suitable winding pattern must therefore always be selected according to the material, machine and required cutting result.
What role does the diameter of a cutting wire play?
The wire diameter influences stability, cutting behaviour and cutting width. Thinner cutting wires may be suitable for finer contours and narrower cuts, but they can be more sensitive to incorrect tension or high loads. Larger diameters provide greater stability and are often used for denser or more resistant materials. However, a thicker wire is not automatically the better choice for every application. The diameter must match the material as well as the wire guides, tensioning system and design of the existing cutting machine.
Which factors influence the cut quality and service life of a cutting wire?
In addition to the material, wire diameter and spiral structure, the settings and condition of the cutting system play an important role. Correct wire tension, running direction, wire speed, feed rate and proper guidance all influence the cutting result and the load placed on the wire. Incorrect tension can cause unstable running, deviations from the required contour or premature wire breakage. Abrasive materials, contamination and damaged guide components can also increase wear. Operating parameters should therefore be set according to the machine manufacturer’s specifications.
Which information is required when ordering a cutting wire?
The first details required are the material to be cut and, where possible, its density. The manufacturer and model of the cutting machine, the exact overall wire length, the wire diameter and the previously used spiral or winding design are also important. Information about the required cut quality and the type of cutting operation can help identify the correct version. When the exact wire designation is unknown, photographs, existing markings or a sample of the current cutting wire can be used as a basis. Custom lengths and adapted designs can then be assessed for the respective machine.
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Cutting wires
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