CNC 4-Axis Hot Wire Wing Cutter
A specialized CAD/CAM utility designed for 4-axis CNC foam cutting. This software synchronizes two independent 2D profiles (Root and Tip) to generate precise G-Code for tapered wings, including complex internal cutouts and automatic stock material management.
I was upset by complexity of most foam cutter programs so I tried to make something simpler !
Basic idea is to draw your profiles and cut outs into a CAD software, save them in dxf format :
-
Layer 0 for the profile
-
Layer 1 for the cut outs attached to the intrados
-
Layer 2 or the cut outs attached to the extrados
Today compatible with Openscad, QCAD and lightburn (polyline export)
Key Features
-
Dual Profile Synchronization: Independently import and transform Root and Tip profiles from DXF (Layer 0).
-
Dual-Layer Cutout Support: Handles internal reinforcements such as spars or wiring on both Intrados (Layer 1) and Extrados (Layer 2).
-
Dynamic Stock Visualization: Automatically calculates required block dimensions based on dihedral, sweep, and safety margins.
-
Advanced Kerf Compensation: Supports asymmetric kerf values for the left and right towers to account for heat dissipation differences.
-
4-Axis G-Code Generation: Produces synchronized X/Y and A/Z movements with controlled transition speeds (G1) to maintain wire tension and accuracy.
Technical Specifications
-
Geometric Transformations : The software uses a Minkowski-style offset for kerf compensation.
-
Scaling: Profiles are normalized to their chord length (Root vs Tip).
-
Alignment: Automatically identifies the Leading Edge (LE) to serve as the pivot point (0,0) for sweep and dihedral calculations.
-
Flipping: Integrated X and Y mirroring to adapt profiles for left/right wing panels without re-designing the CAD file.
CNC Parameters
-
Feedrate: Default cutting speed
-
temperature (S gcode command 0 to 1000)
-
G93 Synchronization: Ensures that both the Root (X/Y) and Tip (A/Z) towers reach their respective destinations at the exact same moment.
-
Constant Kerf: Maintains a consistent “melt-rate” across the entire wire span by controlling the time taken for each segment.
Usage Instructions
-
Import Profiles: Use the File > Open menu to open existing projects (.whw) or use dedicated buttons to load DXF files for the Root and Tip.
-
Define Geometry: Enter the Wing Length, Adjust Back Sweep and Dihedral
-
Note: Root/Tip chords and washout angles are automatically computed from the DXF and cannot be changed manually.
-
Set Material Margins: Input Right/Left Margins and Top/Bottom Margins
-
The Stock Height and Width will update automatically.
-
CNC Origin: The origin is located on the left edge at the bottom of the foam stock.
Simulation & Preview:
Review the 2D path in the workspace. Zoom Pan the 3d view
G-Code Export Options
The software offers several strategies to optimize the path based on the wing design:
-
Top Only: will cut only the top skin (from left to right and exit on right stock side)
-
Bottom Only: will cut only the bottom skin (from left to right and exit on right stock side)
-
**Top + Bottom **: will enter left of stock, then cut top skin then cut the bottom skin (from left to right then right to left and exit on left stock side)
-
Profile + Cutouts: idem as above + second pass to cut cutouts .
Click the Play button to read the Gcode file and simulate the wire motion (in speed up mode)
Gcode is compatible with FluidNC controllers and is supported by GrblHotwire Gcode streamer (UGS works as well)
WihoWi.zip (410.7 KB)
Installation : simply unzip the attached file and run the WihoWi.exe file. You will probably be requested to install all the .Net runtime engine (not very big !). It’s a portable version, no mess up into the registry. To un install delete the whole directory.
This is an alpha version (never released yet…) so please be indulgent and report any bugs or wish list !
Thanks
JP