MecDATA 5-axis robotic milling of a freeform EPS pattern

5-axis simultaneous milling on an industrial robot. MecDATA SCP milled an EPS foam block with a KUKA 6-axis robot fitted with a milling spindle. The part has complex freeform geometry with tapered walls that need simultaneous motion of all robot axes. Toolpaths were prepared and simulated in ENCY Robot, the offline programming solution from ENCY CAD/CAM software.

Programming and simulation before the first cut. MecDATA built the full robot cell — arm, spindle, worktable and stock — inside ENCY Robot to preview motion, check reach and verify tool orientation on the conical surfaces. The verified program was posted to the KUKA controller.

Robotic machining for parts a CNC cannot easily reach. Offline robot programming avoids trial-and-error teaching and delivers a repeatable, verified toolpath. MecDATA uses ENCY Robot to plan multi-axis motion for foam patterns and freeform parts outside the envelope of a 3-axis machine.