The objective of this paper is to develop a multi-functional hotwire cutting system (MHC) using EPS-foam block or plate as the working material. Because the MHC apparatus employs a four-axis synchronized hotwire cutter with the structure of two XY movable heads and a turntable, it allows the easy fabrication of various 3D shapes, such as (1) an axisymmetric shape or a sweeping cross-sectioned pillar shape using the hot-strip in the form of sweeping surface and EPS foam block on the turntable, (2) a polyhedral complex shape using the hotwire and EPS foam block on the turntable, and (3) a ruled surface approximated freeform shape using the hotwire and EPS foam plate. In order to examine the applicability of the developed MHC apparatus, an axisymmetric shape, a polyhedral shape and a large-sized freeform shape were fabricated on the apparatus.