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Workflow

A typical session, from drawing or parametric input to a finished cut. Times below are illustrative; production scales with part size and complexity.

flowchart LR
    A[Parametric input<br/>or SVG] --> B[Generator]
    B --> C[CAM scene<br/>+ nesting]
    C --> D[Toolpath +<br/>safety check]
    D --> E[Pre-cut<br/>jog · zero · dry run]
    E --> F[Cut]
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1. Set up the machine (once)

Open SET → MACHINE and enter:

  • Controller — leave on Auto (detect on connect) for most users.
  • Tower distance (Z), rail length (X), maximum height (Y) — your machine's physical envelope, in mm.
  • Motion — cut, travel, and return speeds; logic mode; approach clearance.
  • Wire and heater — wire length, maximum wire angle, heater mode.
  • 5th axis — enable only if your machine has a rotary axis.

Save once; the values persist.

2. Calibrate the machine (once, plus when material changes)

Open DIAG → STATUS and step through Quick Lab:

  1. STATUS — driver and firmware report green.
  2. SETUP CHECK — pre-flight checklist confirmed.
  3. MOTION TEST — square, travel limits, backlash.
  4. WIRE CAL — cut a reference cube, measure eight points with calipers, save the kerf.
  5. MATERIAL CAL — cut a small reference at the catalogue settings, score the result, save adjustments to the active material preset.

Quick Lab persists between sessions; resume where you left off.

3. Pick a generator

On the GEN page, choose the tab for the part:

  • SHAPES — primitives or SVG import (every tier).
  • NACA — airfoils and tapered wings (AERO pack).
  • DOME / VAULT / BUILDING — architectural (BUILD pack).
  • PIPE / THERMAL — insulation (THERMAL pack).

Set the parameters. The 2D and 3D previews update as you type; every field has a tooltip.

4. Generate the parts

Press GENERATE. The preview shows the cut profiles and, for 4-axis generators, the resulting geometry in 3D.

Press SEND TO CAM (or → CAM). FoamSync hands the parts to the CAM scene.

If the CAM scene already has parts, FoamSync asks REPLACE / ADD / CANCEL:

  • REPLACE clears the scene and loads only the new block.
  • ADD keeps the existing parts and consolidates the new block onto the same physical foam block.
  • CANCEL leaves CAM untouched.

5. Lay out and nest

On the CAM SCENE panel, position the parts:

  • X-Pos, Y-Offset, Height — coarse positioning.
  • ROT 90, MIRROR H, MIRROR V — orientation.
  • SWAP L ↔ R for 4-axis parts when the towers should swap roles.

Press RE-NEST to auto-nest on the foam block. Per-generator strategies (shelf-row stacking for BUILD parts, pair-interlock for pipe shells) pack tighter than single-part nesting.

6. Check the path

Press GENERATE TOOLPATH. The 3D viewport fills with the dense wire trajectory and the JOB status updates:

  • READY — clean path; line and point counts and an ETA appear.
  • ⚠ DANGER — PRESS START TO REVIEW — a check (typically wire angle) wants your attention. Review before cutting.

The 3D view also shows:

  • Translucent red boxes at any overlapping parts (collision check). Resolve by moving or re-nesting.
  • The wire-safety report, opened at any time, with status, max angle, and violation counts.

7. Pre-cut

Before pressing START:

  1. Connect the controller (CONNECT in the top bar). Watch for [OK] Connected and the firmware badge.
  2. Home the machine.
  3. Zero the wire — jog to your stock origin or use ZERO (Quick Actions).
  4. DRY RUN — tick the box, then START. The machine traces the full path cold; confirm it stays on the stock and clears the towers.
  5. Bring the wire to temperature for your material — External: set it by hand; PWM or PID: FoamSync drives it.

8. Cut

Press START.

During the cut:

  • The DRO shows live tower positions.
  • The wire-angle gauge warns as the wire approaches its safe lean limit.
  • The log streams events.
  • FEED % overrides the rate live (slow through a tricky section without regenerating).
  • PAUSE holds motion; STOP ends the job.

The EMERGENCY STOP bar is always visible.

9. After the cut

  • Inspect edges, kerf, and surface. If anything is off, re-run WIRE CAL or MATERIAL CAL.
  • Save the scene to your library if you'll repeat the job.
  • Park the machine; let the wire cool before unloading.

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