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G-code generation software for CNC foam cutter

You’ve built your 4 Axis CNC Foam Cutter and now you need some software to generate g-code for that foam wing or fuselage. If you can afford it then buying software may be the way to go. DevWing Foam 2 and DevFus Foam are very good. I use them for all my projects. I have full tutorials on all of these on this site and YouTube

What software can we use?

The list below is software that can be used to generate 4 axis g-code which I have used and tested. I’ll give you my thoughts on each one so you can decide which may be best for you. If you are going to build a CNC foam cutter then please check how you are going to generate the g-code. I’ve had a few builders make fantastic machines but then try to use free software to make their design only to be disappointed and frustrated when it can’t do what they need. So please do check first.

  • Wing Cutter in G-code (Free)
  • WingWire (Free)
  • Wing Designer (Free)
  • Jedicut (Free)
  • DevWing Foam 2 (License required, trial available)
  • DevFus Foam (License required, trial available)
  • DevFoam Pro (License required, trial available)
  • DevSim Foam (Free)

If you are new to CNC foam cutting then start with Wing Cutter in G-code, WingWire or Wing Designer. These are very easy to use. As you gain more skills and need extra features then this is when you may need to upgrade the paid options. I started this way and now use DevWing Foam and DevFus Foam all the time. I don’t buy RC models anymore so this justifies the costs and it’s much more rewarding in my opinion.

So let’s discuss each one and cover its capabilities such as:-
See the comparison chart further down

  • Aerofoil format supported
  • Kerf setting
  • Wings spars
  • Aileron cutting
  • Wash-out is possible on the tip profile
  • Dihedral
  • Trailing edge thickness
  • Rotating the planform for highly swept wings
  • G93 Feed Mode (very useful for swept wings and when the root is much bigger than the tip profile)

What are DAT files?

mh45 airfoil

All the software here uses a file format called DAT or Selig format. This is basically the coordinates of a wing profile represented as values ranging from 0 to 1. The image above is of an MH45 aerofoil is used in flying wings. There are lots of free sources for DAT, this is one of the main ones http://m-selig.ae.illinois.edu/ads/coord_database.htm

DevWing Foam 2 has a large database of aerofoils that can be added to from the site above as well as being able to use an image or DXF file for the wing plan

Wing G-code Generator

A very easy-to-use g-code generator from http://swarfer.co.za/rc/wire/index.php uses XYUV axis letters. Quite easy to change with a text editor when you have downloaded the files.

Wing Gcode

David also developed a Python script that has more options. I’ve updated David’s script to work with Python3 and some modifications for GRBL. It can use several axis letter variations. You will need to install Python3 but this is available on all Operating Systems or Download the Executable for Windows.

You can install Python3 from here and download the code from the link below. Don’t install it from the Windows App Store it hides some of the install options. There is an option to add Python3 to the PATH so the script below will work by clicking on it.

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Wing G-Code (Python3 script) 33.38 KB 1030 downloads

This script requires Python3 which you can find here https://www.python.org/downloads/ I…
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Wing G-Code (Windows 64bit Executable) 11.92 MB 2854 downloads

This is the Windows Executable version of the Wing G-Code Python script. Just download…

It will also work with LinuxCNC from the Axis interface.

As you can see from the image above the software has an option for wash-out, trailing edge thickness. There are no options for spars, ailerons or setting the kerf(amount allowed for melted foam). But these limitations are only minor. The Kerf value can be accounted for by slightly increasing the size of the root and tip chord. I generally use a 2 mm kerf on my wings. Adding a spare hole is quite easy with a Dremel and a tiling attachment. Have a look at my video here to see how easy it is and it makes an excellent job.

WingWire 4 axis g-code freeware

WingWire 4 axis gcode for foam cutters.

I have used this software briefly. Dominik Schuler the guy that developed also built his own foam cutter using mostly 3d printed parts which are all available on Thingiverse. https://www.thingiverse.com/thing:3676825

Dominik’s software is very good and the only limitations are spars and an aileron cut.

As Dominik has said there isn’t much free software for foam cutters out there so he wrote his own, clever guy, here’s the link on RCGroups https://www.rcgroups.com/forums/showpost.php?p=43256201

Wing Designer for 4 axis CNC foam cutter

This software runs online and is very impressive at http://www.diyrcwings.com/app/ it includes options for spars, dihedral and ailerons. Its only limitation seems to be no option for kerf value but as with Wing G-code generator, you just need to add a little to the root and tip sizes to account for that.

Djordje Mijailovic has developed this software and he ran it on LinuxCNC. You can change the machine parameters so that it will work on the GRBL Mega 5X Hotwire on this website. I’ve run some test cuts and it works well.

Jedicut

Jedicut clarky

JediCut is French software and a few English translations are missing. I don’t use Jedicut and I only ran a couple of tests with it.

If you want to use Jedicut then check my post here on how to set up Jedicut to use it with the GRBL HotWireApplication

For a free program, it’s OK but it does need time to learn. If you are a French speaker then it will be a bit easier. Kerf can be controlled by the Skin Property. There doesn’t seem to be an option for dihedral.

The g-code generated by Jedicut uses Incremental mode G91 so it can look a little strange when you see very small numbers in the xyuz axis. Had a few guys contact me about that.

G1 X0.0521 Y0.2761 A-0.0069 Z-0.0123
G1 X0.1738 Y0.4553 A-0.0156 Z-0.019
G1 X0 Y0.0001 A0 Z0

DevWing Foam 2

This is paid software and cost $150/£110/125 Euro. DevCad who make this software has now introduced a trial of the software. Previously you could download the software for free and everything apart from generating the actual g-code worked until you purchased a license.

The cost might seem a bit high but I don’t buy models anymore I make all mine now and this justifies the cost. Nothing wrong with buying models but for me making and researching the aircraft gives the hobby another dimension. Quite often you can make wings for other people and help recover the costs that way.

DevWing Foam 2 for CNC Foam Cutters

I have a full video series on using the software on YouTube here

DevWing Foam2 is a very comprehensive wing cutting software and has every possible option you can think of. Too many to cover her. It will also allow you to generate cut paths for 3 axis routers to cut rounded wingtips and ribs that can be exported to DXF as well. I use this option to build a 3d model in Fusion 360 of the wing with fuselages. DevWing has the best cutting simulation of all the software here. It’s very useful to see what’s going to happen before you can commit to foam.

DevWing Foam 2 is very good for scale models because you can import an image and with the outline feature get the wing sections planforms very easily. I show how to do this in my video here

DevFus Foam 2

This is the companion program to DevWing Foam 2 and is the only program I’ve found that can produce g-code for fuselages.

t45 goshawk
GosHawk Foam Parts

It again like DevWing Foam needs a license to generate the g-code but if you enjoy building models that aren’t available then DevFus Foam2 is a must. I have a full instructional video series here

I’ve had some guys ask me if it is possible to do this with Jedicut and DXF files and if you have lots of time and are prepared to use up a lot of foam testing then yes it could be possible. Jedicut doesn’t work with all DXF formats, several guys have contacted me over this issue. It just won’t load them.

In my opinion, you would soon get frustrated with JediCut and give up. I’m not being sponsored by DevCad who makes DevFus Foam this is just my honest opinion from using the software and the result you can achieve.

My Hawker Hurricane was built using DevFus Foam as you can see it looks just like a Hurricane and flies fantastic.

Huuricane IID
Finished at Last

DevFoam Pro

DevFoam Pro

DevFoam Pro can generate g-code for many shapes, not just wings and fuselages. You might think this would be better. But DevWing Foam and DevFus Foam have many features especially suited to model airplane design. If you primarily want to work with DXF files or use 5-axis foam cutting then DevFoam Pro is the best choice. Personally, I haven’t used DevFoam Pro as yet but may do in the future.

DevSim CNC Foam (Free)

When you have your g-code generated it’s very important to see what it’s going to do before you waste any foam or possibly damage your machine by running an axis too far.

This is a very useful tool and is identical to DevCNC Foam except you can’t run your machine with it. DevCNC Foam needs a license and is very good. Check my post here for more details

Download DevSim CNC Foam here http://www.devcad.com/eng/devsimcncfoam.asp

DevSim Foa,

G-code generation software comparison

Wing G-codeWing WireWing DesignerJedicutDevWing Foam2DevFoam Pro
DAT FilesYYYYYExport
DXF ImportNNNYY1Y
Wing plan from imageNNNN1YY
Kerf SettingsNYNYYY
Wash-OutYYYYYY4
DihedralNNYNYY4
SparsNNYYYY4
AileronsNNYNYY4
Trailing-Edge ThicknessYYNNYY4
Lightening HolesNNNNYY4
Rotate PlanformNNNNYN
G93NNNNYY
Cutting SimulationNNYY2YY
FreeYYYYN3N3
WindowsYYYYYY
MacYYYNNN
LinuxYYYNNN

1 – Jedicut won’t work with all DXF formats see my post here explaining the issues. DevWing Foam will import a DXF file to use as the wing planform
2 – You can use DevSim Foam to preview the cutting of all of the software here except Jedicut which has its own.

3 – Trial available see the DevCad forum for details https://devcad.forumfree.it/?t=78966499

4 – DevFoam Pro can create this but you will need to design it yourself and control how the g-code path is generated.

G93 is a feed mode that can help when the root and tip aerofoils are much different in size. DevCad software uses this as the default for all G-code. It does make the foam cuts more consistent.

So which one should I choose?

Your first question should be what do I want to make?

For a simple wing and easy-to-use software then any of the free ones will work fine. Jedicut isn’t the easiest to understand so I would suggest one of the others if you are new to this.

Once you need more features then DevWing Foam as it all covered. If you are new to CNC Foam cutting I would first make some simple wings with one of the free options first. Once your skills and needs progress then upgrade to DevWing Foam.

If you want to try to make fuselages in foam then the only option in my opinion is DevFus Foam 2.

If you primarily want to work with DXF files then DevFoam Pro is the best choice.

Hopefully, this post will help you find the right tool and try them all. The DevCad software can be tested in demo mode as explained earlier with a 7-day free trial of the full capabilities.

Happy Foam cutting

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