From sketch to clean G-code in one tool — generate the shape, nest it automatically, cut it precisely.
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FoamSync turns a hot-wire foam cutter into a precision production tool. Instead of hand-drawing every profile and fighting with raw G-code, you generate the shape parametrically, let the cut-safe nester pack it into your stock, and send a clean, kerf-compensated 4-axis toolpath to the machine — or simulate the whole job first on the built-in virtual machine.
Built for the shops that cut EPS / XPS / PU every day: architectural décor, RC and aero foam cores, and thermal insulation.
The point is time. A parametric generator collapses the hours normally spent preparing and converting profiles down to minutes — so the work shifts back to where it belongs: actually cutting parts.
- ⚙️ Parametric generators — domes, vaults, walls, cornices, NACA airfoils, pipe shells, thermal panels. Minutes, not hours.
- 🪛 4-axis cutting (with 5th rotary-axis support) — independent X/Y and U/V towers for tapered and twisted parts.
- 🧩 Auto-nesting — collision-aware packing across every generator, with continuous, clean cut paths.
- 🖥️ Virtual machine — preview and validate the full cut before touching real foam.
- 🎛️ Real-machine control — live DRO, jog, heater control (PWM / PID), one-tap wire-zero.
- 🪶 Cut quality built in — per-material calibrated feed and curvature-adaptive corner slowdown.
- ✏️ Freehand Grid editor — draw any custom contour (snap grid, curved edges, holes, trace-over-image) and save it to your own library.
- 📐 SVG / DXF import — bring in profiles you already have.
Dome (radial / oculus / top-cap), Vault (custom span & height), building-block walls with rounded-corner openings, and a Cornice generator for decorative moulding profiles.
NACA-4 airfoil (any chord / thickness), spar-slot cut-outs with bridge support, 4-axis tilted cuts, and cylindrical or tapered wings with independent root + tip profiles.
Pipe-shell unfolder for cylindrical jackets, and a thermal-panel stack-nester.
Grid Sketch (freehand contour editor + saved-shape library), primitive Shapes, and SVG / DXF import — on every edition, including Lite.
| Lite | Pro | Studio | |
|---|---|---|---|
| CAM core · real machine · virtual simulation | ✓ | ✓ | ✓ |
| SVG/DXF import · Grid Sketch · Shapes | ✓ | ✓ | ✓ |
| Parametric generators | — | add packs | all included |
| Machine seats | 1 | 1 | 3 |
| Customer CRM · priority support | — | — | ✓ |
Pro adds the BUILD / AERO / THERMAL packs à la carte — buy only the workflows you need. Each Lite and Pro licence can be monthly, annual, or a one-time perpetual key; Studio is subscription. Current pricing → foamsyncstudio.com.
Download the latest installer from Releases and run the 7-day trial — a full feature preview in virtual (no-machine) mode, output watermarked, no payment required. Activate a licence to unlock real-machine output and remove the watermark.
Requirements: Windows 10 / 11, 64-bit. See installation and hardware & wiring.
| Introduction | Features |
| Workflow | Tiers & packs |
| Virtual machine | Hardware & wiring |
| Installation | Activation |
| FAQ | Support |
Questions, licences, onboarding → foamsyncstudio.com · or see support.
© 2026 Balcore Systems · Mörfelden-Walldorf, Germany · FoamSync™
This repository hosts public documentation and signed release downloads. FoamSync is proprietary software — see LICENSE.