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FOAMSYNC

Generators & packs

Generators live on the GEN page. Which ones you can use depends on your packs. The CAM core (import, nesting, toolpaths, the machine pages) is in every tier; packs add the parametric generators.

How packs map to generators

PackTab(s) on GENWhat it makes
(none — every tier)SHAPESPrimitive shapes + SVG / DXF import → cut profiles.
BUILDDOME, VAULT, BUILDINGArchitectural / formwork shapes.
AERONACA4-axis airfoils and wings.
THERMALPIPE, THERMALInsulation jackets and panels.
DECORCORNICE, GRID, TEXTDecorative mouldings, freehand custom contours, foam lettering & signs.
  • LITE — SHAPES + imports only, no parametric generators.
  • PRO — pick 1–4 packs (BUILD / AERO / THERMAL / DECOR).
  • STUDIO — all four packs included.

During the trial, every pack is previewed (virtual driver only). See Licensing for what each tier costs and includes.


SHAPES — every tier

The base generator, available on every tier including LITE:

  • SHAPES — primitive profiles: rectangles, rounded rectangles, trapezoids, triangles, circles, ellipses, regular polygons and a quick NACA-4.
  • SVG / DXF import — bring in a drawing; FoamSync turns the closed contours into cut profiles you nest and cut like any other part.

AERO pack — NACA

Four-axis aerodynamic profiles:

  • NACA-4 airfoil generator — set the 4-digit code, chord and thickness.
  • Cylinder or tapered wings — a tapered wing uses a different root and tip profile (e.g. root NACA 8612, tip NACA 4408) and FoamSync sweeps the wire between them.
  • Spar-slot cut-outs with bridge support — pockets for wing spars, with uncut bridges so the plug doesn’t drop mid-cut.
  • 4-axis tilted cuts — independent X/Y (left tower) vs U/V (right tower) motion.
  • Up to 3 spar slots per wing (main / rear / aux), each rectangular or round.
NACA-4 airfoil generator with the 4-digit code, chord and thickness fields
NACA-4 airfoil — set the 4-digit code, chord and thickness; the profile preview updates as you type.
Tapered wing setup with independent root and tip NACA profiles on the two towers
Tapered wing — independent root and tip profiles on the two towers.
Spar slot configuration on the wing — up to three slots, rectangular or round, with bridge support
Spar slots — up to three per wing (main / rear / aux), rectangular or round, with bridge support.

BUILD pack — DOME / VAULT / BUILDING

Architectural and formwork shapes:

  • DOME — radial dome split into rings × sectors, with a solid / oculus / no top-cap, plus lock recesses and an exterior reveal rabbet. The preview shows the dome in 3D and a plan view, with a full material bill (panels, blocks, metres of edging).
  • VAULT — barrel vault with custom span, height and arch profile. The simplest 4-axis shape and a good first cut.
  • BUILDING — building-block walls with rounded-corner openings.
Parametric dome generator with rings, sectors and top-cap controls
DOME — radial split into rings × sectors with solid / oculus / no top-cap.
Barrel-vault generator with span, height and arch profile controls
VAULT — barrel vault with custom span, height and arch profile.

THERMAL pack — PIPE / THERMAL

Insulation and thermal-management cut paths:

  • PIPE — pipe-shell unfolder for cylindrical insulation jackets, with a pair-interlock nester so two half-shells pack into the footprint of one full circle.
  • THERMAL — thermal-panel generator with half-lap rabbet side joints and optional mounting channels on the back, auto-nested across the foam block. The preview shows the panel count per block and the joint/channel layout.
Thermal-panel generator with half-lap rabbet side joints and optional back mounting channels
THERMAL panel — half-lap rabbet side joints and optional back mounting channels.
Detail view of thermal panel parameter controls
Thermal panel — parameter detail.

DECOR pack — CORNICE / GRID / TEXT

Decorative and freeform cut paths — signage, custom contours and architectural trim:

  • CORNICE — decorative moulding-profile generator built from a catalogue of real profiles (cove, ovolo, ogee, crown and more), scaled to your height / width for trim and architectural detailing.
  • GRID SKETCH — draw any custom contour on a snap grid: curved edges, inner holes, mirror symmetry, and a trace-over-image backdrop so you can sketch on top of a reference photo or logo. Save drawings to a private shape library and reload them later instead of redrawing.
  • TEXT — foam letters and signs from any installed font: counters (the holes in A, O, e) are cut as inner pockets, and split letters come out as separate parts.

The generator workflow

  1. Pick a tab on GEN and set parameters. The preview (2D profile and/or 3D) updates as you type; each field has a tooltip.
  2. Press GENERATE.
  3. Send the result onward:
    • SEND TO CAM (or → CAM) drops the parts into the CAM scene.
    • When the CAM scene already holds parts, FoamSync asks REPLACE / ADD / CANCEL so you can either start fresh or consolidate the new parts onto the same block.
  4. Save reusable setups to the LIBRARY for later recall.

What’s next

Take your parts into CAM & nesting, then run the cut.