DPW - Dual Wire Abrasive Profile Saw

  • Dual Profile Wire - DPW Dual head Abrasive wire profile saw
  • Dual Profile Wire - DPW Dual head Abrasive wire profile saw
  • Dual Profile Wire - DPW Dual head Abrasive wire profile saw
  • Dual Profile Wire - DPW Dual head Abrasive wire profile saw
  • Dual Profile Wire - DPW Dual head Abrasive wire profile saw
  • Dual Profile Wire - DPW Dual head Abrasive wire profile saw
  • Dual Profile Wire - DPW Dual head Abrasive wire profile saw

DPW Specifications [Downloadable PDF]

DPW - Dual Head Abrasive Wire Profile Saw

ESCO’s DPW (short for Dual ProfileMatic Wire) employs both vertical and horizontal cutting wire heads wrapping the functionality of two machines into one robust package.

The DPW contour wire saw may be used to process both flexible PU foams and rigid PU foams such as Polyisocyanurate (PIR). ESCO’s DPW profile wire saw can create complex finished parts by passing the foam from one cutting head to another.

Common Applications for the DPW

Block Preparation

Since the DPW contour wire saw can process all six sides of the block of foam the DPW may be used as a blocking saw especially for rigid PU and PIR that have a very hard outer skin.


Many times after block preparation is complete fabricators will then use the DPW dual wire contour saw for sheeting the clean block into sheets. Since the cutting wire can process in any directions sheeting is an efficient process on the DPW.

Profile Cutting

Processing flexible PU block for furniture or seating applications. With the horizontal cutting head the machine will cut the profile pattern of the cushion. Once complete the machine passes the block to the vertical cutting head to cut the profile cut block into sheet of the desired thickness. For more complex cushions more details can be made with the vertical cutting instead of making straight cuts.

Rough Machining / Preprocessing

Rough machining of foam and other technical materials is another use of the DPW. The idea with this cutting strategy is to use the DPW to oversize the desired rough geometry of the part profile. The DPW wire saw can process raw materials with higher yields because the rough part geometry can be nested in high yield layouts within the block versus traditional methods where the block is cut into a series of smaller blocks then the parts are machine to final specification. Rough machining with the DPW is also can save labor, machining time and overall throughput (more parts/unit of time). Since the rough geometry has been completed on the DPW the total machining time required from machining centers is far less than starting from a small block.

Industries utilizing the DPW

  • Insulation
  • Furniture
  • Upholstery
  • Packaging
  • Medical
  • Sleep / Mattress
  • Marine
  • Automotive
  • Acoustic & Radio Frequency (RF) Management

Commonly Processed Materials

  • Poluisocyanurate ( PIR )
  • Trymer
  • Rigid PU
  • FoamGlas®
  • Mineral Wool / Mineral Fiber
  • Calcium Silicate
  • Expanded Polystyrene ( EPS )
  • Crosslinked Polyethylene ( XLPE )
  • Polyethylene
  • Expanded Polypropylene ( EPP )
  • Phenolic Foams
  • Rebond Foam
  • Reticulated Foam
  • Flexible Polyurethanes
  • High Resilience Foams ( HR Foam )
  • Non-woven Fibers
  • Flexible Foam
  • Crosslinked PU

DPW Features


  • PC based operator terminal
  • Industrial handheld remote control
  • Powered adjustable upper blade guide assembly
  • Air-conditioned main control panel
  • Siemens CNC Motion Controls
  • ESCODraw Standard


  • Air-conditioned PC Terminal
  • ESCODraw PRO - Includes advanced nesting software and cut path generator
  • Dust Collection System


  • PLC Control with PC interface
  • Controls are mounted on a freestanding pedestal


  • Input voltage 380-500VAC/3phase/50-60hz
  • Clean dry compressed air


DPW Model Specifications
DPW 36-55 DPW 50-88
Cutting Height 36" [914 MM] 50" [1270 MM]
Cutting Width 55" [1397 MM] 88" [2235 MM]
Max cutting speed 70 FT/MIN [21.33 M/MIN] 70 FT/MIN [21.33 M/MIN]
Floor Space Required
Width 220" [5588 MM] 290" [7366 MM]
Length 330" [8382 MM] 330" [8382 MM]
Height 125" [3175 MM] 150" [3810 MM]

Advanced Profile Management (APM) Software

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