Solidworks to HotWire cutter?

[jlcortes]

Hello,

I am searching software to generate gcodes for 4axis hotwire in order to cut

I am using profilli pro to generate gcode for MACH3, profilli works great with wing airfoils but i am trying to make complex sharpes for airframes cutting and profilli don´t have the control than i need.

i have try Camworks, modified postprocesor for MACH3 axis but not working correctly because mach3 seems not to support gcode commands to manage wire holder offsets.



This is my machine


and the project:



Any idea about control a hotwire machine with real CAD-CAM system?

[jlcortes]

Hello,

I have cut a great number of parts with my new machine, but it have all kind of problems!



i am thinking about build another machine, but i need some advice of experts!

my big problem is wire tensioner, i have search in google and i have found a nice tensioner system from hotwiremachines:
http://www.hotwiremachines.com/MAGIC-REEL.cfm

it have a simple roller to do a 90 degree wire direcion change and it have a spiral reel to keep a constant wire tension?

that no the problem, my main question is this:

How to compensate roller diameter and offset?, there are any way with MACH3?

[jlcortes]

let me explain it better, it is and example,

in red, tower position(only vertical moviment)
in blue, wire
in white, finished part shape

first, teorical


second, efect of roller diameter

[kahuna]

Look for a simple wire EDM cam package