EPS foam mold milling for automotive body panels on a KUKA robot

Custom automotive body work
Shared by Simaxis Engenharia — the team helps a Brazilian shop that mills EPS foam masters for customised automotive body panels. The finished blank shown at the end of the reel carries the concentric ridges of a ball-nose finishing pass, ready to be used as a plug for composite layup.

KUKA cell driven by ENCY Robot
Toolpaths for the "dianteiro dir" (right-front) fender part are generated in ENCY CAD/CAM software using its ENCY Robot module and posted to a KUKA KR 200 L170 arm. The operations tree lists one roughing waterline and two scallop-height finishing passes with a ball-nose Metalcenter tool, verified against the full cell kinematics.

Why robot milling
Large curved automotive geometries outrun classic 3-axis mills — the robot arm brings the reach and continuous 5-axis freedom needed for a single-setup finish.