Installation

FoamSync DE is a self-contained desktop application. No internet connection is required to run it.

System Requirements

Installing

1. 1
   Download the installerObtain the FoamSync DE installer package from your distributor or foamsyncstudio.com.
2. 2
   Run the installerDouble-click the installer and follow the on-screen steps. Accept the license agreement when prompted.
3. 3
   Launch FoamSync DEUse the desktop shortcut or Start Menu entry. The application opens directly — no additional setup is required.

Licensing

FoamSync DE is commercial software. A short trial is included so you can evaluate every feature before activating. See the Licensing & Tiers page for tier comparison, activation flow, and the renewal banner explained.

Licensing & Tiers

FoamSync DE ships with a 7-day trial. Three commercial tiers cover everything from one-machine shops to multi-site fabricators.

The 7-day Trial (DEMO)

Every fresh install starts in DEMO mode. All design features are unlocked so you can evaluate every generator, but the real-machine connection is locked — only the Virtual Driver runs. The trial is 7 days from first launch.

• The header shows DEMO · 6d with the remaining day count.
• All generators (BUILD, GEN, DIAG) are usable; G-code preview works end-to-end.
• Connect button stays available but real hardware is gated until activation.

Tier Comparison

Packs (PRO only)

PRO licences are sold as the base plus any combination of packs. BUILD unlocks the architectural generators (Vault, Dome, Building, Openings, Cornice, ICF). AERO adds the NACA airfoil generator and inner spar slots. THERMAL adds the Thermal panel and Pipe shell generators. STUDIO already includes all three packs.

Activation Flow

Click the trial banner at the top of the window (or open the activation dialog from SET → COMPANY → OPEN LICENCE DIALOG). The activation dialog shows your Hardware ID at the top — a 16-character fingerprint of this computer.

Method 1 — Paste a Perpetual key

If you purchased a perpetual licence (one-time purchase, no expiry), paste the key into the input field and press ACTIVATE. The licence binds to this machine and the dialog closes. The tier badge in the header flips to PRO or STUDIO.

Method 2 — Drop a .dat file

Subscriptions (monthly / yearly) and air-gapped installations use a hardware-bound licence file. Your distributor builds a license.dat against the Hardware ID you sent them. Click DROP LICENSE FILE, pick the .dat, and the dialog accepts it after signature verification.

The Renewal Banner

Subscription licences (monthly / yearly) and DEMO both surface their expiry in the same coloured banner at the top of the window:

Click anywhere on the banner to open the activation dialog. Perpetual licences never show a renewal banner.

Where licences live

FoamSync stores the activated licence under your user data directory. On Windows that's %APPDATA%\.foamsync\license.dat. It is signed against your Hardware ID — copying it to another machine will not activate that machine; you must request a fresh activation.

"Licence file retired" notice

If you ever see a "License file retired" dialog on launch, it means the previous license.dat failed cryptographic verification (corrupt, tampered, or signed by an old key). The file is moved aside to license.dat.obsolete and the app falls back to DEMO mode. Re-activate via key paste or fresh .dat.

Replacing a Machine

If you replace the computer running FoamSync, the Hardware ID will change and the existing licence will no longer activate. Contact your distributor with both the old and new Hardware IDs — STUDIO licences allow up to 3 bound machines without paperwork, and PRO seat transfers are handled case-by-case.

First Run

Learn the application using Virtual Driver mode — no CNC machine needed.

Virtual Driver Mode

When FoamSync starts, it defaults to Virtual Driver mode. In this mode the application simulates a connected machine so you can explore every feature safely before touching real hardware.

The top-right area of the window shows VIRTUAL_DRIVER and a VIRTUAL badge. No machine is needed.

Your First Part — Step by Step

1. 1
   Go to BUILD Click the BUILD icon in the left sidebar (the diamond symbol).
2. 2
   Choose a generator Click one of the tabs at the top: VAULT, DOME, THERMAL, PIPE, or OPENINGS.
3. 3
   Set your dimensions Fill in the parameters on the left panel — for example, the clear opening width and height for an arch vault.
4. 4
   Click GENERATE The GENERATE button at the bottom left runs the generator. A preview appears in the centre and the part list fills at the bottom.
5. 5
   Send a block to CAM In the right panel under PENDING, click a block to select it, then click → QUEUE. The block moves to CAM QUEUE. Click → CAM.
6. 6
   Preview in CAM The CAM page shows a top-down view of the foam block with all cutting paths. Review the layout, then click CUT to send to EXEC.
7. 7
   Run in EXEC EXEC shows the G-code and a live position display. In Virtual mode, click START to simulate the cut. The machine position updates in real time.

Connecting Your Machine

FoamSync supports any 4-axis hotwire CNC running Marlin or GRBL firmware. Connection is automatic.

Supported Firmware

Connecting

1. 1
   Plug in the machine Connect your CNC controller to the computer via USB. Wait for the operating system to install the driver (usually automatic).
2. 2
   Select the port In the top-right area of FoamSync, open the port dropdown and select the COM port your machine is on (e.g. COM3).
3. 3
   Click CONNECT Press the CONNECT button. FoamSync automatically detects whether the firmware is Marlin or GRBL and configures itself accordingly.
4. 4
   Confirm connection The status indicator turns green and shows the detected firmware name (e.g. MARLIN or GRBL). The current machine position appears in the JOG page.

Disconnecting

Click DISCONNECT in the top-right area. Always disconnect cleanly before unplugging the USB cable.

Troubleshooting Connection

Interface Overview

FoamSync uses a consistent three-zone layout across all pages.

Layout Zones

Left Sidebar — Page Navigation

A vertical strip of icon buttons switches between the main pages. The active page is highlighted in orange. From top to bottom:

Top Bar — Machine Status

The top bar shows the current connection status on the right side:

• VIRTUAL — Virtual driver active, no hardware
• Port selector dropdown — choose your COM port
• CONNECT / DISCONNECT — toggle connection
• Firmware name badge after successful connection

Status Bar — Bottom

A thin bar at the very bottom shows real-time feedback: current operation, errors, and confirmation messages. Watch this bar when generating parts or sending to CAM.

Keyboard & Mouse

JOG Page

Manual control of the CNC machine. Use JOG to position the wire, test movements, and home the machine before every job.

Axis Controls

The JOG page has two sets of directional controls — one for each tower (Left and Right). Each tower moves independently in two directions:

Use the paired movement buttons to move both towers simultaneously by the same amount, keeping the wire level.

Step Size

Select the jog distance from the step-size buttons: 0.1 · 1 · 10 · 50 · 100 mm. Each click of a directional button moves the selected axis by this amount.

Position Display

Current machine coordinates are shown in real time for all four axes. Use this to verify position before starting a cut.

Homing

Click HOME ALL to run the homing sequence. FoamSync raises both wire ends to a safe height, moves horizontally to the home position, then lowers — in that order, to avoid collisions.

Stop Controls

BUILD Page

The BUILD page is where you design parts and prepare them for cutting. Choose a generator, set dimensions, generate, then send to CAM.

Generator Tabs

At the top of the BUILD page are five tabs. Each tab is a shape generator for a different part type:

Left Panel — Parameters

Each generator has its own set of parameters in the left panel. Parameters are grouped into sections:

• Shape dimensions — the size of the opening, shell, or panel you want to produce
• EPS Block — the dimensions of the foam blocks you have available
• Joints / connectors — settings for how parts lock together

Click − or + to adjust values, or scroll the mouse wheel over a field. Click RST to restore all values to defaults.

Centre Panel — Preview

An isometric 3D preview updates automatically as you change parameters, showing what the finished assembly will look like. Colours indicate part types:

• Green — left-side pieces
• Blue — right-side pieces
• Gold — joint features (pазы / step joints)
• Black area — the void (opening being framed)

Parts List — Bottom

After generating, the parts list shows every unique piece with its dimensions and cutting status. Click any row to see a detailed profile view on the right.

PENDING and CAM QUEUE — Right Panel

After generation, each foam block appears in the PENDING list. To send a block to CAM:

1. 1
   Click a block in PENDING to select it (it highlights). The → QUEUE button becomes active.
2. 2
   Click → QUEUE to move the block to the CAM QUEUE section below.
3. 3
   Click → CAM to send the selected queued block to the CAM page for cutting path setup.

GENERATE Button

Click GENERATE at any time to re-run the generator with the current parameters. Previous results are replaced. The status bar at the bottom shows a summary: number of part types, total pieces, blocks required, and estimated EPS volume.

CAM Page

Arrange parts on the foam block, preview the toolpath in 3D, review pre-flight warnings, and send the cutting program to the machine.

SCENE MANAGER (left panel)

Lists everything currently in the cutting scene — generator-produced parts, dropped SVG / DXF imports, and merged blocks. Each row shows the model name and (for SVG / DXF) the file name. Buttons under the list:

A status line above the SAVE button shows "Placed N / M" where M is the expected part count from the project file. "5 missing" means the project expects 5 parts but only some are placed — drag-drop or generate the missing ones.

TRANSFORM (left panel, below SCENE MANAGER)

Buttons that act on the currently selected part:

• ROT 90° — rotate in 90° increments
• MIRROR H / V — flip horizontally or vertically
• SWAP L↔R (4-AXIS) — for tapered parts, swap the front and back contours
• X-Pos / Y-Offset / Height — fine-tune position and Z-axis depth

3D Toolpath View (centre / right)

The main viewport shows a 3D rendering of the foam block, the wire path for every part, and the swept surfaces between the two tower paths. Controls top-right: TOP · FRONT · SIDE · ISO · FIT snap to standard views.

Reading the path colours

• Orange — left-tower path
• Green — right-tower path (same as left for cylindrical cuts)
• Soft gold — ruled surface between the towers (the wire sweep)
• Bright orange — entry / exit lead tails
• Dim blue-grey — rapid transit moves (wire in air)
• Red — toolpath overflow (segments leaving the foam block — must be fixed)

Pre-Flight Warnings (console strip)

Below the 3D viewport is a colour-tabbed log: ERR · WARN · OK · INFO · DEBUG. The pre-flight pass writes wire-angle results, boundary violations, and SVG face-skip diagnostics here. See the Wire Safety page for what triggers each severity.

HUD & Position Display (top)

The top bar shows live position of all four axes (L-HORIZ · L-VERT · R-HORIZ · R-VERT), a LEAN gauge for the current wire angle, and the machine status (READY · CONNECTING · CUTTING · ESTOP). The trial / expiry banner sits just above this bar.

Sending to Machine

1. 1
   Review the layout — confirm no parts are red (overflow) and the pre-flight strip shows OK.
2. 2
   Set feed rate for your foam density (defaults come from SET → MATERIAL).
3. 3
   Click CUT — FoamSync generates the G-code, runs final pre-flight, and switches to the EXEC page automatically.

EXEC Page

Execute the cutting program, monitor machine position, and control the run in real time.

Before Starting

Controls

G-code Monitor

The console panel shows G-code lines as they are sent, and responses from the machine. Useful for diagnosing any movement issues. You do not need to understand G-code to operate FoamSync — the monitor is for reference only.

Position Display

The current position of all four axes is shown and updated continuously during the cut. Watch this to confirm the machine is moving as expected.

Progress

A progress bar and line counter show how much of the program has been executed. The estimated time remaining is shown when the machine is running.

SET Page

Machine setup, material library, and licence administration. Two tabs — MACHINE for hardware, COMPANY for branding and licence.

MACHINE tab

The MACHINE tab arranges settings into a 2×2 grid of cards, full-width on the page. Each card groups one logical concern.

Card — HARDWARE

Card — WIRE & HEATER

Card — SPEED & PATH

Card — MATERIAL & STOCK

The Material selector is the active EPS recipe — density, kerf, recommended speed and heater settings. FoamSync ships with standard recipes (EPS 25, EPS 35, XPS, etc.); custom recipes can be added via EDIT MATERIALS. Stock defines the foam block dimensions: Stock X (width), Stock Y (height), Stock Z (length = wire travel direction). These are the defaults for every generator and CAM session.

COMPANY tab

Brand identity, integrations, and the active licence. Same 2-column card grid as MACHINE.

Card — COMPANY IDENTITY

Workshop name, phone, website. These fields appear on PDF batch documentation generated from CAM and on the support bundle export.

Card — INTEGRATIONS

Optional CRM webhook URL. Every time a batch is sent from BUILD to CAM, FoamSync POSTs a JSON summary to this URL (date, part list, foam volume). Useful for stitching cuts into an ERP / order-tracking system. Leave blank to disable.

Card — TIER & LICENCE (full-width)

Shows the current tier, unlocked packs, machine seats, expiry, and a OPEN LICENCE DIALOG button for activation / re-activation. STUDIO tier shows extra entitlements: priority support queue, multi-machine deployment (up to 3), custom dev hours. See Licensing & Tiers for the full activation flow.

LIB Page

A history of every batch you have generated. Reload any previous job with one click.

Batch History

Every time you click GENERATE on the BUILD page and then send a batch to CAM, FoamSync saves the job automatically. The LIB page lists all saved batches in reverse chronological order.

Each Entry Shows

• Date and time of generation
• Generator type (Vault, Dome, Thermal, Pipe, Openings)
• Key dimensions
• Number of parts and blocks

Reloading a Batch

1. 1
   Click a batch entry in the list to select it.
2. 2
   Click LOAD — FoamSync switches to the BUILD page, restores all parameters, and re-generates the parts automatically.

This is useful for repeating a job, or for making minor adjustments to a previously successful configuration.

GEN Page

Curve-based shape generators — Shapes (rounded rectangles, ellipses) and NACA airfoils. Pure 2D profiles that the wire sweeps through the foam.

What goes here vs BUILD

The split is by output complexity: BUILD produces full multi-part assemblies (a whole vault, a whole dome, a window frame). GEN produces a single profile that becomes one cut. Use GEN when you want a quick airfoil or a parametric shape to drop into CAM; use BUILD when you want a building component.

SHAPES sub-tab

Parametric primitives: rounded rectangles, ellipses, generic curve sketches. Set the dimensions, click GENERATE, drop the result into CAM. Available on every tier.

NACA sub-tab

Aerospace airfoil generator. Requires the AERO pack on PRO, or any STUDIO licence. Type a 4-digit NACA code (e.g. 2412), set chord and kerf, optionally add up to 3 inner spar slots, and the generator emits the airfoil outline plus inner-contour cuts. See NACA Airfoil Generator for the full feature set.

DIAG Page

Diagnostics, calibration helpers, and the encrypted support bundle. Open this page when something is wrong — or when support asks you to.

What DIAG shows

• System info — OS version, FoamSync build, active firmware, connected port.
• Quick Lab — built-in calibration runs for motion, wire kerf, and material settings.
• Quick Start button — opens the 5-page introductory manual in your default PDF viewer.
• Support bundle — exports a single encrypted file you email to support; contains the last debug logs, machine config, and recent job history. Encrypted with the FoamSync support public key so only the support team can read it.

Calibration runs

Each calibration run produces a result block you can apply back to SET → MATERIAL & STOCK with one click, or save as a named recipe for future jobs.

Wire Safety & Pre-Flight

Before every real-machine cut, FoamSync runs a pre-flight analysis. This page explains what it checks and what to do when it complains.

The Wire Angle Limit

A hot wire under tension behaves like a stiff string between two towers. If the two towers are too far out of sync (one ahead of the other), the wire leans away from vertical — beyond a few degrees, the wire can stretch, slip, or break and the cut quality drops sharply.

FoamSync caches a maximum lean angle (wire angle limit) in SET → WIRE & HEATER. Default 15°. The pre-flight pass scans the planned toolpath point-by-point and computes the worst-case lean.

Pre-Flight Severity Levels

Overflow Detection

The CAM 3D viewport flags any toolpath section that leaves the foam block (the wire would cut air). Affected segments turn red in the preview; the warnings strip lists which part overflows and by how much. Fix by adjusting the part position in the SCENE MANAGER, the part height, or by switching to a larger block in SET.

Block Boundary Check

Independently of overflow, the pre-flight also verifies that the cut path stays inside the stock block in all four directions. If a generator output exceeds stock_offset_x + stock_x or any other edge, the warning surfaces as "<model> overflows foam block: right X 2453.2 > block end 1000.0" in the CAM console.

SVG / DXF Face Diagnostics

When you import an SVG or DXF with multiple closed loops (e.g. a letter with holes, or a moulding profile with internal cut-outs), FoamSync classifies each loop as outer or inner and routes inner pockets first. Loops that are too small or degenerate are reported individually in the CAM console — for example "<file> face #3: bbox 0.20×0.00 mm — dropped (sub-0.5 mm degenerate)". This lets you see exactly which face was skipped and why, rather than wondering why some part of your import didn't cut.

Vault Generator

Generates EPS panels for barrel vault ceilings, tunnel linings, and archway structures.

What It Produces

The vault generator divides a full arch into a series of curved panels (segments around the arc) arranged in rings (sections along the length of the vault). Each panel is a trapezoidal curved piece that, when assembled, forms a complete barrel vault.

Panels from adjacent rings interlock using built-in connector pins that are cut into the foam profile automatically.

Parameters

Assembly

Vault panels are numbered. Assemble ring by ring, starting from one end. Within each ring, place panels around the circle and press connector pins together. Apply EPS adhesive at the joints for a permanent bond.

Dome & Sphere Generator

Generates curved EPS panels for hemispherical and partial dome structures, including the optional top cap (solid or oculus).

What It Produces

The dome is divided into horizontal rings (latitude bands) and vertical sectors (like orange segments). Each unique panel shape is calculated once; identical panels within the same ring are cut as a batch.

The schematic preview shows the assembled cross-section and the current state of the top cap: solid, oculus (circular skylight opening), or no cap.

Parameters

Assembly

Start from the bottom ring and work upward. Within each ring, all panels are identical. Align connector pins, apply EPS adhesive, and press joints together. The top ring panels meet at the apex; if Cap mode is Solid or Oculus, the cap piece is the last to fit.

Thermal Panel Generator

Generates flat rectangular EPS insulation panels for walls, roofs, and floors.

What It Produces

Simple flat rectangular panels cut to exact dimensions. Panels can include optional tongue-and-groove edge profiles on any side for airtight, self-aligning joints between adjacent panels.

Parameters

Fitting Multiple Panels

FoamSync automatically calculates how many panels fit side-by-side in the block and how many blocks are required. The status bar shows the fill ratio (how much foam is used vs. wasted).

Pipe Shell Generator

Generates half-cylindrical EPS insulation shells that clamp around pipes and ducts. Requires the THERMAL pack (or any STUDIO licence).

What It Produces

Each shell is a half-cylinder (180° arc). Two identical shells are assembled around a pipe. The flat joining faces include a V-groove lock or rectangular tongue-and-groove so the two halves hold together without adhesive. Both halves are cut from the same program — just rotate one 180° for assembly.

Pair-aware nesting and cutting

Pipe shells come naturally as mirror-pair twins. FoamSync's dedicated Pipe nester arranges them in an interlocking pattern — alternating rows flat-up/flat-down so two halves share the same diameter line and pack into a full-circle footprint. The CAM toolpath then keeps each pair back-to-back in cut order, so the wire transits a few millimetres between pair-mates instead of returning to the approach zone. Together this gives ~30 halves per 1000×1000 mm block (vs ~10 with the generic raster nester) and saves around 15–25% of the inter-shell transit time on multi-shell jobs.

Parameters

Assembly

1. 1
   Place the first shell under the pipe with the groove face up.
2. 2
   Rotate the second shell 180° and place it on top. The tongue of one half slides into the groove of the other on both sides simultaneously.
3. 3
   Press together firmly. No adhesive required for temporary insulation; use EPS adhesive for permanent installations.

Openings Generator

Generates EPS foam frame panels for door and window openings — the frame you see around the opening, not the opening itself.

What It Produces

Each frame is produced as a set of stackable pieces:

• JAMB pieces — straight rectangular sections forming the vertical sides of the frame. Multiple JAMB pieces stack vertically if the frame is taller than your foam block.
• ARCH piece — the L-shaped top piece containing the arch curve and the solid bearing zone above it.
• SILL pieces (windows only) — flat panels that fill the area below the window opening.

Every piece type comes in a Left (L) and Right (R) half. The two halves are joined at the centre with a step joint. Cut one of each and assemble symmetrically.

Opening Types

Arch Styles

Parameters

How Pieces Stack

If the frame height exceeds your Block H setting, FoamSync automatically divides the vertical jamb section into multiple JAMB pieces. Each joint between stacked pieces has a tab-and-slot step joint built into the profile — a rectangular tab on the lower piece fits into a matching slot on the upper piece. No separate hardware needed.

Assembly Order

1. 1
   Stack the JAMB pieces vertically, pressing each tab into the slot of the piece above. Apply EPS adhesive at each joint.
2. 2
   Attach the ARCH piece on top of the JAMB stack — the slot on the bottom of the ARCH receives the tab on the top JAMB piece.
3. 3
   Join Left and Right halves — slide the ledge of the Right half into the notch of the Left half at the centre joint.
4. 4
   For windows: fit the SILL panels below the frame in the same L + R manner.

NACA Airfoil Generator

Generates aerospace-grade airfoil profiles from the standard NACA 4-digit family, with optional inner spar slots for structural beams. Requires the AERO pack (or any STUDIO licence).

What It Produces

A closed 2D airfoil contour ready to drop into CAM, plus optional inner pocket cuts. Supports two modes:

• CYLINDER — same airfoil on both towers. Produces a straight wing section. Works on any machine including 2.5D.
• TAPERED — different airfoils at root and tip. Produces a wing with varying chord and/or thickness along the span. Requires a true 4-axis machine with independent vertical axes.

NACA Code

Type the standard 4-digit code:

Example: 2412 means 2% camber at 40% chord, 12% thick. Sub-tabs CAMBER / THICKNESS / POINTS / TAPER RATIO show the live curve breakdown.

Chord, Kerf, Resolution

Spar Slots

Wings need structural beams (spars) passing through the airfoil from one rib to the next. The Spar Slots section lets you cut up to 3 inner pockets per airfoil — one per spar. Each slot is one row with the following controls:

Pre-set spar layouts

The PRESETS ▾ dropdown loads common layouts in one click — RC trainer, sailplane twin-spar, flying wing, heavy lift. Each preset clears the current slots first.

Validation

Slot geometry is validated live. Two rules:

• The slot edge must leave at least 5 mm of material to the airfoil surface at the local thickness.
• Two slots must be at least 5 mm apart.

Violations show as a red banner above the GENERATE button. The CAM-bound action is gated — fix the slot dimensions or position before sending to CAM.

Building Generator

Generates rounded-rectangle building panels — exterior walls with corner pieces and straight wall sections, including step-joint locks.

What It Produces

The Building generator decomposes a rounded-rectangle building footprint into:

• Corner pieces — quarter-arc panels at each corner of the building. The number of corners equals 4 (one per building corner) regardless of size.
• Wall pieces — straight panels between corners. Lengths are calculated so each piece fits within the foam block, splitting longer walls into multiple stackable sections.

All pieces lock together at their joining edges using tongue-and-groove step joints — symmetric, so any wall fits any corner without needing to track piece orientation.

Parameters

Assembly

Lay the bottom course first — alternate corner and wall pieces around the perimeter, pressing the tongue of one into the groove of the next. Apply EPS adhesive at each joint. Stack the next course on top, again alternating, and offset the wall-piece seams between courses so vertical joints don't line up. The tongue-and-groove pattern is symmetric, so installation is one orientation per piece type.

Full Workflow

A complete job from design to cut — every step in order.

Step-by-Step

1. 1
   Set up machine dimensions (SET page) Enter your foam block stock sizes and machine travel limits. Do this once; it becomes the default for all jobs.
2. 2
   Connect hardware (top-right) Select the COM port, click CONNECT, wait for firmware confirmation. Then HOME ALL from the JOG page.
3. 3
   Design parts (BUILD page) Choose a generator tab, enter dimensions, click GENERATE. Review the 3D preview and parts list.
4. 4
   Queue blocks for cutting (BUILD page — right panel) For each block in PENDING: click the block, click → QUEUE, click → CAM.
5. 5
   Configure cutting settings (CAM page) Review the layout, set feed rate and wire temperature for your foam, click CUT.
6. 6
   Place foam block in machine Physically position the foam block, secure it, and confirm the wire starting position using JOG.
7. 7
   Start cutting (EXEC page) Click START. Monitor progress. Use PAUSE if you need to inspect mid-cut.
8. 8
   Repeat for remaining blocks Return to BUILD, select the next block from PENDING, and repeat from step 4.
9. 9
   Assemble Fit parts together using the joint features, apply EPS adhesive at bonded joints.

Assembly & Joints

FoamSync parts are designed to fit together mechanically. No separate hardware is required for most assemblies.

Step Joint (Паз / Half-Lap)

Used for joining two parts along a straight edge — for example, the Left and Right halves of an opening frame, or stacked JAMB sections. One part has a rectangular notch (recess) and the other has a matching ledge (protrusion). They slide together and resist pulling apart.

The joint is formed in the 2D cutting profile, so no secondary work is needed. The dimensions are set by the Step depth and Step height parameters in the generator.

Tab-and-Slot Joint

Used for vertically stacking JAMB sections. The lower piece has a tab (rectangular bump) on its top face. The upper piece has a matching slot (cavity) on its bottom face. Stack from bottom up, pressing each tab into the slot above.

V-Groove Lock (Pipe Shells)

The two halves of a pipe shell lock together using a V-shaped groove on the flat joining faces. When one shell is rotated 180° relative to the other, the V-tongue of each half fits into the V-groove of the other — the joint self-centres and holds under light compression.

Connector Pins (Vault and Dome)

Adjacent panels in vaults and domes interlock with rectangular pins. The pin profile is cut into both joining edges — one edge has the pin protruding, the adjacent panel has the matching slot. Pins resist sliding and keep panels aligned during assembly.

Adhesive Recommendations

• Use EPS-compatible adhesive (polyurethane foam adhesive or special EPS glue). Standard solvent-based contact adhesives dissolve EPS — do not use them.
• Apply adhesive to one surface, press together, and hold for 60 seconds.
• For large assemblies, use temporary pins or tape to hold parts while the adhesive cures.

FAQ & Troubleshooting

Answers to common questions and solutions to frequent problems.

Software

The QUEUE button stays greyed out after I send a block to CAM.

Click on the next block in the PENDING list to select it. After a block is moved to the queue, the selection is cleared — click the row again to re-activate the button.

The preview shows nothing after I click GENERATE.

Check the status bar at the bottom of the screen for an error message. Most commonly, one or more dimensions are out of range — for example, the outer diameter exceeds the block width. Adjust the parameters and try again.

The part dimensions in the list say 0×0 mm.

This usually means the generator produced a degenerate part — often caused by a block size that is too small to fit even one part. Increase Block W or Block H and re-generate.

Can I use the same job file on a different computer?

Yes. Jobs saved to LIB are stored as files in the application data folder. You can copy these files to another machine running FoamSync DE. Use the same file path structure.

Machine & Connection

FoamSync doesn't see my COM port.

The controller board driver may not be installed. Common controllers use CH340, CP2102, or FTDI chips — download and install the appropriate driver for your board. Unplug and replug the USB after installation.

The machine moves in the wrong direction.

Go to SET and check the axis mapping. The Left Horizontal, Left Vertical, Right Horizontal, and Right Vertical roles must each be assigned to the correct firmware axis letter. Consult your firmware configuration.

The wire cuts too slowly / burns the foam.

Reduce wire temperature or increase feed rate. Heavier-density EPS requires more power; lighter EPS cuts at lower temperatures. Start conservatively and test on a scrap piece.

The machine stopped mid-cut and I had to E-STOP. Can I resume?

FoamSync does not support mid-program resume after an E-STOP. Home the machine, reposition the foam block at the correct starting point, and re-send the cutting program from the beginning.

Parts & Quality

The cut surface has a wavy pattern.

This indicates wire vibration — usually caused by feed rate too high or wire tension too low. Slow down the feed rate or increase wire tension at the machine.

Parts don't fit together after cutting.

Check the kerf setting in the generator. The kerf is the thickness of material the wire removes. If kerf is set too small, joints will be tight; too large and there will be gaps. Measure your actual wire kerf on a test cut and enter the accurate value.

The arch piece is too tall for my block.

Increase Block H on the BUILD page to match a taller block. Alternatively, reduce the arch opening height, or use the Flat arch style which produces a shorter arch piece.

Licensing

I lost my licence file. Can the distributor re-issue it?

Yes — your distributor can re-issue a license.dat bound to the same Hardware ID at no charge. Send them the Hardware ID shown in the activation dialog or in SET → COMPANY → TIER & LICENCE.

The Hardware ID changed after a Windows update / driver reinstall.

FoamSync tolerates one component change automatically. If two parts of the fingerprint changed (e.g. network card driver replaced and a disk swap), re-activation is required. Contact your distributor with the new Hardware ID.

Can I run FoamSync on two computers with one licence?

LITE and PRO are single-machine licences. STUDIO supports up to 3 bound machines on the same key — request activation for each Hardware ID from your distributor.

I see "Licence file retired" on launch.

The previous license.dat failed cryptographic verification and was moved to license.dat.obsolete. The app falls back to DEMO; re-activate via key paste or a fresh .dat drop. See Licensing & Tiers.

SVG Import

I dropped an SVG and only part of it cuts.

The CAM console (the colour-tabbed log strip) will list every face that was dropped and why — typical reasons are sub-0.5 mm degenerate loops, < 3-point contours, or inner pockets that couldn't be paired with a lead-in path. Edit the SVG to remove the offending loops and re-drop.

The SVG has holes (e.g. letter "B") but only the outer outline cuts.

FoamSync detects inner contours and routes them before the outer cut so the part is released only at the end of the program. However, inner holes do not have bridge cuts in 1.0 — the cut-out plug separates fully during the cut. For thin foam this is usually fine; for thick blocks consider designing the part with built-in bridges in the SVG itself, or use the BUILD-page generators (which include bridges where needed).

For further support, contact support@foamsyncstudio.com or visit foamsyncstudio.com.