Wing Hot Wire CNC foam cutter & Gcode streamer

As an RC planes enthusiast, I already designed several planes using foam cutting technics.

To do this you will need a foam cutter machine and a "board" to pilot it. Regarding the board, I already published a cheap FluidNC 4 axis controller.

This controller has already proven to work very well. But it needs "software" to produce the Gcode and to control the board. This is exactly what this project is dealing with !

Although several solutions does already exist, none of them were (IMHO) simple and powerful enough for my needs... 

So I wrote two applications :

• WiHoWI (Wing hot Wire) devoted to design the Gcode file of the wings

• hoWiGs (hot Wire Gcode Sender) devoted to drive the FluidNC controller

All the project including software (freeware) is on my hackadays pages 

WiHoWi 

features :

• dxf import of root and tip profiles

• dxf import of cutouts (intrados/extrados)

• dxf import of synchro points for profiles

• automatic flipping 

• Gcode generation (multi passes or single pass)

• 3dView

• generates Gcode compatible with CNC 4axes (timely consistant)

• Kerf compensation

hoWiGS

It's a Gcode streamer for FluidNC 4 axes CNC (foam cutter)

features

Connectivity & Control

• FluidNC Integration: Optimized for 4-axis (XY AZ) control over USB (scan and connect choosen port at predefined default baud rate 115200).

• Real-time Interaction: Input and send custom G-code commands directly to the board via a dedicated console.

• Emergency Management: Reset the machine after alarms, pause/resume ongoing cuts, or "Kill" a cut instantly with a safety long-click on the Stop button.

3D Visualization & Workspace

• Dual-Plane Preview: Real-time 3D display showing profiles mapped both on the physical foam stock and on the motor projection planes.

• Smart Parameter Loading: Automatically extracts cutting parameters (wire length, wing length, etc.) from G-code files generated by WiHoWi, or allows for manual entry.

• Origin Management: Easily define your Work Origin and return to it with a single click.

 Advanced Jogging

• Precision Jogging: Move axes by fixed, user-defined increments at a chosen feedrate.

• Continuous Jogging: Dynamic movement that lasts as long as the mouse button is pressed, providing a natural feel for wire positioning.

---

 Thermal Management

• Integrated Heater Control: Toggle the wire heater and adjust temperature/power levels.

• Real-time Tuning: Modify temperature settings on the fly even while the G-code is currently streaming.

 FeedRate Management

• Integrated FeedRate Control: adjust feedrate for jogging

• Real-time Tuning: Modify FeedRate settings on the fly even while the G-code is currently streaming.

---

Specialized Cutting Modes

• Guillotine Mode: Quickly trim stock faces without complex G-code.

  • position your wire

  • set heather on at choosen temperature

  • continuous jog (or predefined distance value) to cut a face

• Automatic Dihedral Guillotine: Specialized mode to cut the root or tip faces at the correct angle to account for wing dihedral. 

  • set the angle value 

  • set heater on at choosen temperature

  • position your wire

  • continuous jog (or predefined distance value) to cut a vertical dihedral angle