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Supported hardware

Machine topology

FoamSync is built for a 4-axis hot-wire CNC with two towers, one on each side of the foam block. Each tower carries the wire on a two-axis carriage — X / Y on the left tower, U / V on the right. The wire spans between the towers; independent tower motion produces tapered, swept, and conical cuts. Synced tower motion produces straight (2-axis-equivalent) cuts.

A 5th rotational axis is supported optionally — useful for parts where the block rotates between cuts.

Controllers and firmware

FoamSync auto-detects the firmware on connect. Supported:

Firmware Notes
GRBL Common for hot-wire builds. Auto-detected.
GRBL-H-Par Hot-wire parallel variant of GRBL. Auto-detected.
Marlin Auto-detected.

If auto-detect picks the wrong firmware or the handshake stalls, you can set the controller explicitly under SET → MACHINE → Controller.

Connection

USB serial. FoamSync lists available COM ports in the top bar; press CONNECT to handshake. Common gotchas:

  • The wrong COM port is selected. Refresh the port list after plugging in.
  • Another application is holding the port (Arduino IDE, a previous FoamSync instance, another sender). Close it.
  • A charge-only USB cable. Use a data-capable cable.
  • USB power management dropping the port mid-session. Use a powered hub if needed.

Machine setup values

Configured under SET → MACHINE:

  • Tower distance (Z), rail length (X), maximum height (Y) — the physical work envelope, in mm. These bound the work area and set the soft limits.
  • Motion — cut, travel, and return speeds; logic mode; approach clearance.
  • Wire and heater — wire length, maximum wire angle, heater mode.
  • 5th axis — enable if present, with an increment per tick.

Heater modes

  • External — operator-driven (dimmer or PSU). FoamSync only moves the wire. Recommended starting point.
  • Board PWM — controller-driven open-loop power %.
  • Board PID — controller-driven closed-loop to a target temperature.

Switching from External to a board-driven mode requires a one-time safety acknowledgement per release (fuse, detector, attended operation).

Materials

Built-in presets:

  • EPS 15, 25, 40 kg/m³
  • XPS 30, 45 kg/m³
  • PU 40 kg/m³

Custom materials accept any density and cut parameters. Each preset stores kerf, feed, temperature, and power; MATERIAL CAL in Quick Lab tunes the preset to the actual batch.

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