FoamCut Workbench

Interface example

A FreeCAD External Workbench for creating Gcode for 4 and 5 axis CNC foam cutting machine.

Originally it based on set of macros written by Andrei Bezborodov (HardRock) - member of FreeCad community. His idea was build 5 axis foam cutter and use FreeCad as a platform to produce output for this machine. Since he has no time to continue development further I decided to step in. Hopefully our effort will be appreciated.

So far there are many limitation but I'm working on fixes. If you want to contribute to this project - you highly welcome! Enjoy!

Installation

Automatic Installation

Not available for now

Manual Installation

Linux:

cd ~/FreeCAD/Mod/ 
git clone https://github.com/Shkolik/Foamcut.git

Windows:

cd %APPDATA%\FreeCAD\Mod 
git clone https://github.com/Shkolik/Foamcut.git

When you restart FreeCAD, "FoamCut" workbench should now show up in the workbench dropdown list.

Video Tutorial

Quick workflow example: FoamCut workflow

Old tutorials (using macro), but workflow is the same (in Russian). ЧПУ пенорезка на 5 осей. Подготовка задания в FreeCAD.

Example file

Example file to play with workbench

Tools

Init Machine

Creates machine configuration

Config example

Create path

Creates path by 2 given opposite edges. Opposite faces also supported - command will try to find opposite edges and create a path for each edge pair.

Path example

Create projection

Creates projection path from selected single edge, multiple edges or face. Projection is basically emulation of 2 axis macine with 4 axis. Can be used for preparing foam blocks, cutting "hershi-bar" wings or decorative signs. Projection and Path objects cannot be mixed in a same route. Command will create projection for each edge.

Projection example

Create move path

Creates path from selected vertex in specified direction

Move example

Join

Creates path between 2 selected vertices

Join example

Enter

Creates enter path from safe height to selected vertex

Enter example

Exit

Creates exit path to the safe height from selected vertex

Exit example

Rotation

Rotate selected body around 5th axis

Rotation example

Route

Creates a cutting route from selected paths and rotations. Objects should be selected in a right order before executing command. Kerf compensation currently supported and kerf direction can be specified for each object (except Rotation, Path and Projection) independently or for whole route.

Route example

Generate Gcode

Generates Gcode and save it to the specified file

Mirror Gcode

Mirror selected GCODE file around YZ plane. Useful for cutting symmetrical pieces like wing consoles. At the moment there is no validation or changing metadata in resulted files - be careful using this command.

Limitations/TODO

Machine setup is not parametric. Path and other objects will not be recalculated if you change working area in a middle of the process. But object themself parametric and will be recalculated in case target body parameters got changed. DONE
~~There should be only one machine per file. So far objects strongly depends on that.~~ DONE
~~Need to add foam block representation in setup.~~ DONE
~~5th axis location not configurable for now~~ DONE
~~Machine origin is hardcoded and locates in a working area center~~ DONE
~~No kerf settings. User can overcome it by modifying model (create Draft offset and use it as reference for paths )~~ DONE
It's highly recommended to export your model as .STEP file, import it in new document and start from there, or . Since all objects depends on underlying geometry you, in most cases, cannot transform your model or part of it to place inside working area. It's higher priority TODO. DONE with some limitation
Cannot create path by selecting faces. In many cases it could be very useful to just select 2 faces and create path/route based on their edges (somewhat like loft) instead of selecting edges one by one. DONE
Configuration setup panel widget
~~Make helper geometry unpicable~~ Done
~~G93 mode~~ - for now I don't se a reason to implement it. GRBL controller take care of simultaneous axis movements.
~~mirroring gcode tool~~ DONE
~~Create path by vertex and edge~~ Done
~~Edge projection normal to the working plane~~ DONE
~~Toggle projection lines~~ DONE
~~Add package.xml~~ DONE
Automatically place model inside machine and create foam block around it. Right now it's recommended to create a parametric copy of your model (like Draft.Clone) after placing model where you want, to reset model placement.
Add video tutorial
Add examples
many more I forgot for sure ;)

Discussion

Please offer feedback or connect with the developer via the dedicated FreeCAD forum thread.

License

GNU Lesser General Public License v2.1

Shkolik / Foamcut

readme