Getting 3D Out of Fusion for Cutting in 2.5D on CNC Router

[oliver]

At our furniture company we primarily use sub-contractors to cut our 2.5D designs on 3-axis CNC routers. We use several companies. They all accept differing types of machine code from their programming tools (they each have their own 'tool-pathing' files that they generate from our complied dxfs). 

When conveying the designs to our partners we have to run an impossibly tiresome and error prone workflow:

Model 3D part in FUSION360 > Create Sketch on Floating Plane > Project common-depth features to Sketch > Export sketch as DXF > [repeat for all depths of cut and then for perimeter cuts] > Take all dxfs into AutoCAD manually and align each layer with a name and colour > Export from DWG as DXF.

Then our partners essentially do the opposite to get their programs to export the machine code to their machines.

Then whenever we need to update a design we need to do the whole process again and hope that the updated features are captured by our partners. Fast forward several prototyping phases because the process is very error prone and ££££ then we have a product again. 

This is tiresome, expensive and error prone. 

Is there another way?

[MattWynn]

Well I see no one else has answered so I'll chime in.

I've been in this business for 30+ years.  Back in the day, DXF files were something everyone could work with, for design and communicating with manufacturing.  There were lots of processes developed that forced machining geometry into DXF geometry - by using layers, colors, linestyles, z heights to have special meaning.  It is very tiresome, expensive and error prone - but it worked and was less expensive than editing G code files by hand. The old joke about "that's the way it was and we liked it" comes to mind.  https://youtu.be/ut3jqRlElOM?t=39 

But this is the year 2021, we have 3D CAD/CAM and machine tools that are very affordable.  The 'other way' is to design in 3D and communicate with your vendors in 3D.  You can do the CAM yourself and they can postprocess it for their machines, or they can do the CAM.  I've seen chatter in our groups about never using DXF again.  I know change happens slowly in manufacturing, but we also know that manufacturers that do not change do not survive.

Designing in 3D and using CAM is less expensive than modifying DXF files by hand.  Find a subcontractor that will go on this journey with you and give them all your business.

[oliver]

Thank you so much, at least I'm not going mad or simply misunderstanding the art of the possible. 

You mention doing the CAM myself and then getting them to post process it. This sounds promising, how do I process the CAM myself? Is this the tools in 'Manufacture' within Fusion?

Sorry to be a dummy

[MattWynn]

Yes, the Maufacture workspace has the tools to go from design to toolpath to machine code that will control machines that will make objects. 

CAM is a big field, but there is lots (maybe too much) information to get you started.

Fortunately, Fusion has good tutorials built in (with sample models), online documentation, and a vibrant community (here, youTube, Facebook, etc.).  To replace DXF geometry, you would probably use mostly the 2D contour, pocket, and drill operations.

Open the learning panel from the help menu (? icon on the upper right) and click around in the manufacture workspace.  And go to CAM samples near the bottom on the data panel on the left.

[MattWynn]

@oliver welcome to a new year!

Have you had the opportunity to learn about using CAM to get away from sending magic DXF files to your vendors?