Dev Foam Software Series Explained

DevCad provides several Foam applications for generating g-code for your project. Whether that is an RC model airplane or a generic foam shape. I have been contacted a few times asking me which one should I use.

So in this post, I’ll explain the foam applications, and then you can decide which one is best for you. I’ve been using DevCad software for many years and have done several projects with it.

In my opinion, the software from DevCad is the best software for foam cutting.

Foam Software from DevCad

These are for generating g-code. DevFoam for any shape, DevWing Foam for wings and DevFus Foam for fuselages

All of the above generate the g-code for your project.

DevCNC Foam doesn’t generate the g-code, but will connect to your controller and send the g-code.

DevSim CNC Foam is basically the same as DevCNC Foam, but it just runs a simulation for the foam cutting job, and it’s free. Very useful for verifying your g-code.

So let’s discuss each one and why you might use it.

DevFoam

This software comes in different versions depending on your needs, and that’s reflected in the price.

DevFoam is used for creating generic shapes and can import from popular CAD packages and raster image files like jpeg. It has many features, which you can see in the table on their website.

Why would you use DevFoam?

The main reasons are

• Cutting text and generic shapes
• Importing CAD Files like DXF/DWG
• Using 5 axes for complex foam shapes. Quite often for building work.

Look at FliteTest’s video where they created a massive B-17 using DevFoam to create the foam parts from a CAD design.

If you like to use a CAD program for your designs, then Dev Foam is probably the best choice.
I don’t know of any other software that will generate 5-axis g-code for a CNC foam cutter with a rotating table. So if you need to use a rotating 5-axis foam cutter, Dev Foam is the only solution I know of.

DevWing Foam

So why would you use DevWing Foam instead of DevFoam?

There are several reasons;-

• You don’t need to learn how to use a CAD package to create your designs. All the wing designs are created in the software. Even after using their software for several years, I still find options I didn’t realise it had.
• It has a massive database of aerofoils, and you can import more as well.
• It’s very easy to use in a wizard-like interface. With DevFoam, you need to understand which options you need.
• There are many options for wing design. Such as washout dihedral, lightning holes, spars, rotating wings to save foam and many more. You can do this in DevFoam but you have to do all the calculations yourself and make sure the hot wire synchro points are suitable. DevWing Foam does all this for you.

One option I find very useful for swept-back wings is the ability to generate g-code to cut both foam cores in one cut job. One core is inverted, and this ensures that both cores come out the same.

You can also generate 3-axis g-code for a CNC router to make wing ribs and the wing tip.

I have a full video series on DevWing Foam. Check this page for the link

DevFus Foam

This again means you don’t need to learn a CAD package, and it uses a wizard-like DevWing Foam.
There are several options to help with your design, like spars and cutting the wing seat and canopy. I have a tutorial for this and DevWing Foam on the channel, which explains how to use it.

I’ve made a Hawker Hurricane and a BAE Hawk using DevFus Foam, and both came out really well.

Free Software Limitations

None of the free software supports G93, a feed mode that works particularly well for foam cutting, especially on complex shapes. This helps to produce a good cut on wings and fuselages where the wire travels at different speeds on the left and right carriage of the foam cutter.

To produce an accurate foam piece, you need to have the correct kerf value. This is the amount of foam melted by the hot wire. All the Dev Foam series have options for setting this and a special function called Smart Kerf. This is very helpful on wings where the root is much bigger than the tip. I haven’t seen any option like this on free software.

DevCNC Foam

I do get questions about this software quite often. The main one is how to generate the g-code with DevCNC Foam?

This software is used to send g-code to your controller. You can use it with g-code generated from free software, as well as the DevFoam series.

So why would you use DevCNC Foam instead of the GRBL HotWire Mega 5X on the website?
There are a few reasons.

• Firstly, the GRBL Hotwire Mega 5X will only work on Arduino Mega 2560-based boards, whereas DevCNC Foam will work on several boards from the Arduino Uno, Mega and Duo 32-bit. Plus a few specialised boards.
• It supports 5 axes, so you can use a rotary table.
• The firmware is automatically installed when you first connect your new controller board. No need to upload the firmware.
• You can change the axis letters to suit the g-code generator. If you use any of the Dev Foam series, there is no need to worry about axis letters, as they will launch DevCNC Foam from the last page and transfer it automatically.
• You don’t have to use the Dev software to generate g-code; all the free g-code generators will work with it.
• You can record a sequence of commands to create a macro you can run and save for future use
• A game controller is supported to move each axis and can be customised to suit your needs

Summary

So I hope that helps in deciding which is the best option for you if you are thinking of using one of these software packages.
I use DevWing Foam, Dev Fus Foam and DevCNC Foam. I haven’t yet found the need to use DevFoam, but maybe in a future project, I will.

Please remember that you can try all of the Dev software for free, fully functional for 7 days and then after that, you won’t be able to generate the g-code or in the case of DevCNC foam, the total movement is limited to 400mm.

In my opinion, the Dev Cad software for foam cutting is the best and most comprehensive. The free software packages are fine for simple wings, but as you progress, they are limited.

I can justify the license cost because I haven’t purchased an ARTF kit for several years now. If you enjoy building, then I can highly recommend the Dev Cad software, and I use nothing else.

Happy foam cutting