VERSION 9 CAD/CAM/CNC Tutorial

“After today I will be able to…”

…Draw a part in FlashCut CAD …Configure fabrication heads
…Use the Shape Library …Run the CNC controller to cut a
…Import a color image part

…Make a toolpath in FlashCut …Use advanced CADCAM tools

CAM …Design and cut pipe
…Generate a nest …Use Smart360™ to produce
…Generate G-Code holes
 Tutorial Lesson List
Lesson 1 - Features, Installation, and Lesson 7 - Advanced CAD/CAM Tools
Licensing
Lesson 8 - More Advanced CAD Tools
Lesson 2 - Drawing in CAD
Lesson 9 - Cutting a Part in CNC
Lesson 3 - Making a Toolpath in CAM
Lesson 10 - Diagnostics and Help
Lesson 4 - Using the Shape Library
Lesson 11 - Pipe Cutting
Lesson 5 - Importing an Image CAD/CAM/CNC

Lesson 6 -Fabrication Heads & Cut Lesson 12 - Using Smart360TM

Charts
 Lesson 1:
Features, Installation, and Licensing
Lesson 1 - Features, Installation, and Licensing

Application Features
Lesson 1 - Features, Installation, and Licensing

CAD Features
Lesson 1 - Features, Installation, and Licensing

CAM Features
Lesson 1 - Features, Installation, and Licensing

CNC Features
Lesson 1 - Features, Installation, and Licensing

Installation
1. Launch the FlashCut CNC Version 9 installer
2. Choose Run in the following
Lesson 1 - Features, Installation, and Licensing

Installation
● If you have a previous version of
V9, it will be automatically
uninstalled.
● If you already have V5-V8, it will
remain installed.
Lesson 1 - Features, Installation, and Licensing

Installation
● The installer will launch after any
previous version is successfully
uninstalled.
Lesson 1 - Features, Installation, and Licensing

Installation
● Choose the folder location for
the software to install.
Lesson 1 - Features, Installation, and Licensing

Installation
● Confirm the chosen settings.
Lesson 1 - Features, Installation, and Licensing

Installation
● Automatically install required
applications.
Lesson 1 - Features, Installation, and Licensing

Installation
● The application is successfully
installed.
Lesson 1 - Features, Installation, and Licensing

Licensing
1. Each system comes with two software licenses:
• One license embedded in the controller for any PC that connects
• One “software-only” license which can be activated on any PC— regardless of being
connected to the controller
2. Licensing will allow you to save CAD/CAM files, create G-Code, and send G-Code to the
controller
3. An unlicensed program will run in “Evaluation Mode”; this will allow the user to play with the
CAD/CAM features and create G-Code of 25 lines or less
4. To activate a “software-only” license , first go to the License window

First, click the

key icon.
Then, locate the
appropriate license in
the pop-up menu.
Lesson 1 - Features, Installation, and Licensing

Activating PC License
5. Make sure you have an internet connection with
the firewall off or with settings that will allow for an
6
outside program to write to your hard disk

6. Press the Activate PC License button

7
7. Copy the License Key from the licensing email
and paste it in the License Key text box by typing or
8
using the Paste From Clipboard option

8. Click the License Software button

Lesson 1 - Features, Installation, and Licensing

Activating PC License
● The features that you are licensed for are
noted under a green key

● Each purchased license is good for one PC

and one controller

● The PC license can be transferred to a new

PC by first selecting the Deactivate PC
License button on the original PC and then
re-activating the license on a new PC using
the same steps as above

● You must have an internet connection on both

PCs for this to work
Lesson 1 - Features, Installation, and Licensing

Activating PC License

● Once you have activated your license, you

can now view the activated features listed on
the license panel

● The green key indicates activated features,

and the grey lock indicates features in
evaluation mode
Lesson 1 - Features, Installation, and Licensing

Activating Controller License

1. To activate the controller license, you must do the following:
a. Make sure your USB cable is connected and your controller is turned on
b. Go to the CNC tab
c. Hit the Connect button – which will turn green when connected successfully

2. Once you are connected to the controller, it is only necessary to do a “software only”
license if you want to license a second PC or if the controller PC will not always be
connected to the controller
 Lesson 2:
Drawing in CAD
Lesson 2 - Drawing in CAD

Create Tools
Create Tools circled on toolbar below

“Create” section labeled below.

Elliptical
Line Rectangle Arc Circle Text Point Polygon Ellipse Spline
Arc
Lesson 2 - Drawing in CAD

Shape Library
Shape Library circled on toolbar below

The Shape Library provides

premade shapes you can
manipulate and add to your
drawing field
Lesson 2 - Drawing in CAD

Modify Tools
Modify Tools circled on toolbar below

“Modify” section labelled below

● Fix Drawing
● Curved Text
● Cut
● Explode
Corner ● Group
Extend Trim Scale Offset ● Ungroup
Treatment
● Ungroup All
Lesson 2 - Drawing in CAD

Transform Tools
Transform Tools circled on toolbar below

“Transform” section labelled below

● Boolean Operations
● Shape Welding
● Arc Fitting
● Mirror
Copy Delete Move Rotate Measure Bridge ● Linear Matrix
PRO
● Circular Matrix
Lesson 2 - Drawing in CAD

Toggle Snap and Palate Tools

Snap Tools: Palate Tools:

● All Snaps Off ● Midpoint ● Part Shading On/Off

● Center ● Nearest ● Palate Grid On/Off
● Endpoint ● Parallel
● Grid ● Perpendicular
● Horizontal/ Vertical ● Quadrant
● Intersection ● Tangent
Lesson 2 - Drawing in CAD

Importing Files
Bitmaps – BMP, DIB, JPG,
JPEG, PNG, PBM, PGM, PPM,
SR, RAS, TIFF, and TIF

Color Image Centerline Silhouette

DXF/DWG
Drawings
Lesson 2 - Drawing in CAD

Making a Bracket

Open a new 2D file

and start by clicking
on the CAD tab to
begin your drawing
Lesson 2 - Drawing in CAD

Making a Bracket Step 1: Make a 6” by 6” Square.

A A. Choose the Rectangle tool
B. Define the dimensions and
placement by either clicking
opposite corners with your
mouse or setting the XY
coordinates in the parameters
panel
a. Make sure the lower left
B corner of the square is
B located at (0,0)
C. Click the green check at the
bottom of the parameters panel
to “Check It In”

C
Lesson 2 - Drawing in CAD

Making a Bracket Step 2: Make a Polyline.

A. Choose the Line tool in the
toolbar
B. Select Continuous Line in the
parameters panel
C. Select the following three
B points with your mouse or by
A C typing the XY coordinates:
(4,6), (4,2), (0,2).
C D. Click the green check to
confirm your drawing
E. To end the polyline, click the
red X or the Esc key

D
E
Lesson 2 - Drawing in CAD

Making a Bracket Step 3: Trim the Excess.

A. Select the Trim tool
B. Hover your mouse over the
line segment you want to
trim; it will turn red
B&C A a. Note: the portion of
the line segment that
you will keep will turn
green
C. Click the red segment to
remove
Lesson 2 - Drawing in CAD

Making a Bracket
Step 4: Draw a Circle.
A. Select the Circle tool
B. Select the center point
(1,1) with your mouse or
type the XY coordinates in
the parameter panel
A
C. Set the diameter to 1 with
B
your mouse or enter the
C value into the parameter
panel
Lesson 2 - Drawing in CAD

Making a Bracket D
Step 5: Copy the Circle.
A. Select the existing circle;
it will turn red
B. Select the Copy tool
C. Select the center of the
existing circle as a
B reference point
D. Select the new center
D point at (5,5) with your
mouse or enter (4,4) for
C the Offset in the
parameters panel
E. Check it in

E
Lesson 2 - Drawing in CAD

Making a Bracket Step 6: Create a Fillet.

A. Select the inner corner or
two adjacent lines to
fillet; they will turn red
B. Choose the Corner
Treatment tool in the
toolbar
B C. Select Fillet in the
C parameters panel
A D. Adjust the radius of the
edge with your mouse or
enter a radius of 1.0 in
the parameters panel
D E. Check it in

E
Lesson 2 - Drawing in CAD

Making a Bracket Step 7: Create a Chamfer.

A. Select the lower right
corner or the two
adjacent lines to
chamfer; they will turn
red
B B. Choose the Corner
C Treatment tool again
C. Select Chamfer in the
parameters panel
D D. Either drag to size or
enter a length of 1.0 for
Distance 1 & 2
E. Check it in
A

E
Lesson 2 - Drawing in CAD

Making a Bracket Step 8: Save the Drawing.

A. Select the Save icon or
from the File menu
choose Save
B. Name the file “Bracket”
when prompted to do so
C. Hit the Save button

C
 Lesson 3:
Making a Toolpath in CAM
Lesson 3 - Making a Toolpath in CAM

Using CAM: Selection Tool

● Used to select groups of entities:

○ Breaks – All; Perimeter; Cutouts
○ Operations – All; Perimeter; Cutouts; Open
Profiles; Marks; Center Pierces; Drilling
○ Geometry – All; Perimeter; Cutouts; Holes;
Other
✸ Ctrl-click will also add or subtract
entities from the current selection
Lesson 3 - Making a Toolpath in CAM

Using CAM: Display Options

Convenient way of displaying and hiding:
● Cutting Direction
● Kerf Compensation
● Perimeter of Material
● Parts
● Part Numbers
● Rapid Moves
● Toolpath
● Part Shading
● Gridlines
Lesson 3 - Making a Toolpath in CAM

Using CAM: G-Code Generation

Use to Generate and Edit G-Code

Lesson 3 - Making a Toolpath in CAM

Using CAM: CAM Actions

● Project Settings
● Fab Head (Plasma) Settings
● Break Settings
● Tab Settings
● Grid Nesting
● True-Shape Nesting
● Nesting Report
● Cutting Order
● Cutting Simulation
● Reset Tool Path
Lesson 3 - Making a Toolpath in CAM

Using CAM: View Tools

● Sheet Number
● Pan
● Zoom
● Zoom Window
● Zoom Workpiece Extents
● Zoom Toolpath Extents
Lesson 3 - Making a Toolpath in CAM

Making a Toolpath in CAM Step 1: Transfer CAD Bracket

Drawing to CAM.
A. Hit the double arrow button
between CAD and CAM
a. An initial toolpath will be
generated with your
default parameters
Lesson 3 - Making a Toolpath in CAM
Step 2: Setting Lead-Ins and Lead-Outs.
A. Click the Selection button; a drop
Making a Toolpath in CAM down menu will appear
a. Hover over the Breaks option
A and select Cutout Breaks
B. On the parameters panel, find the
General section, and set overburn to 0
C. In the Lead-In section, specify the
following:
B
a. Type: Arc
b. Radius: 0.125
E&F
c. Angle: 120
C
D. In the Lead-Out section, select no
lead-out
D
E. With mouse, move lead-in to desired
location by dragging the breakpoint
F. Dynamically adjust parameters by
dragging the lead-in head
G G. Check it in
Lesson 3 - Making a Toolpath in CAM
Step 3: Setting Workpiece
Dimensions.
Making a Toolpath in CAM A. Click the Zoom to Workpiece
Extents button
C B. Select Project Settings icon in the
CAM Actions section on toolbar
C. In the parameters panel, make
sure Default Cutting Head is
correct
E a. Check it in
B D. Select sheet outline; it will turn
A
D green
F E. In the parameters panel, Set
workpiece dimensions to 48” wide
x 24” long
F. Set material type and properties
G. Check it in
G
Lesson 3 - Making a Toolpath in CAM

Making a Toolpath in CAM

Step 4: Grid Nesting.
A. Select the Grid Nesting button
in the CAM Actions section
B. Set Count to 18
C. Set Spacing X/Y to 1.0
D. Click Start Nesting
B
E. Check it in
A
D

E
Lesson 3 - Making a Toolpath in CAM

Making a Toolpath in CAM

Step 5: True-Shape Nesting.
A. Select the True-Shape Nesting
button in the CAM Actions
section
B B. Set Count to 30
A
E C. In the Parameters section, set
spacing to 0.25”
C D. Set Min Distance from Sheet to
1”
D
E. Click Start Nesting
F. Check it in

F
Lesson 3 - Making a Toolpath in CAM

Nesting Direction: Horizontally

Making a Toolpath in CAM

Step 6: Nesting Direction.
A. Remain in True-Shape Nesting
B. Set Count to 14
C. In the Parameters section, set spacing to 0.25”
D. Set Min Distance from Sheet to 1” E

A.
B.
C.
D.
E. Locate the property Nesting Direction and
experiment with each option
E a. Note how the direction determines the
manner in which each piece fills the
sheet, starting at the corner specified
in Nest from Corner
F. Click Start Nesting
G. Check it in
Nesting Direction: Vertically
Lesson 3 - Making a Toolpath in CAM

Making a Toolpath in CAM

Step 6: Transform from CAD/CAM File to CNC.
A. Click Save icon to save CAD/CAM file
B. Hit the double arrow button between CAM and
CNC
A
C. G-Code will be generated for the toolpath in CAM
and the CNC panel will automatically open

Note: If you click the CNC

button, the CNC panel will
B open, but it will not load the
G-Code for the current
toolpath in CAM
 Lesson 4:
Shape Library
Lesson 4 - Shape Library

Exploring Shape Library

A

Step 1: Open a New File

A. Click the New File icon or select
C
New from the File menu
B. Choose 2D for the file type
C. Select the Shape Tool
Lesson 4 - Shape Library

Exploring Shape Library

Note: Once completed shape is created, they can
then be edited using any of the drawing tools
Step 2: Customize a Shape
A. Scroll through the given shapes and
choose one
B. Edit the shape properties in the
parameters panel
C. Choose a Pivot Point location
D. Drag the shape with your mouse or
type the XY coordinates into the boxes
B
A labelled Insertion Point X/Y to specify
D the shape’s location
E. Check it in
C

E
Lesson 4 - Shape Library

Exploring Shape Library

A Step 3: Save the Drawing

A. Select the Save icon
or from the File menu
click Save
B. Name the file after
B
your customized
shape
C. Hit the Save button
C
 Lesson 5:
Image Import
Lesson 5 - Image Import

Importing Silhouette Images

Step 1: Convert to Geometry
A. Choose the Import Silhouette icon from
the Image Import dropdown B
B. Browse to an image file (See page 27 for A
acceptable file types, and example of
silhouette image) C
C. Alter the properties in the parameters
panel to your liking
D. Check it in

D
Lesson 5 - Image Import

Importing Silhouette Images

Step 2: Edit the Geometry
A. Click the Ungroup button in the
toolbar and select your image
a. This will make the shape
editable as individual line
A
C segments
b. Use alt+click on any line
segment to “chain select”
an entire feature
B. Delete the eyes
B C. Choose the Ellipse Tool and
replace the eyes with ellipses
Lesson 5 - Image Import

Importing Silhouette Images

Step 3: Create the Toolpath
A. Hit the double arrows
between CAD and CAM to
push the drawing to CAM
A B and automatically create a
tool path
B. Hit the double arrows icon to
generate G-Code and send
it to the CNC module
Lesson 5 - Image Import

Importing Silhouette Images

Step 4: Cut the Parts in CNC
Lesson 5 - Image Import

Importing Color Images

Step 1: Convert to Geometry

A. Choose the Import Color Image
icon from the Image Import
A dropdown
B B. Browse to an image file (See
page 27 for acceptable file
types, and example of
silhouette image)
a. Images with strong
contrast work best
C C. Alter the properties in the
parameters panel to your liking
D. Check it in
D
Lesson 5 - Image Import

Importing Color Images

Step 2: Organize Layers

A. Click on the Layer Tool at the
bar on the bottom of the screen
B. Click on the visibility icon of
each layer to determine what
geometry is associate with each
layer
C. Delete the layers that are not
necessary
B
D. Click on an individual layer and
C rename it by typing in the name
field

A
D
Lesson 5 - Image Import

Importing Color Images

Step 3: Nest the Parts

A. Go to CAM
B. Follow the steps previously
executed for Nesting
a. Notice how the stars fill
the sheet as individual
parts, which may not be
desirable
Lesson 5 - Image Import

Importing Color Images

Step 4: Combine Layers

A. Return to CAD
B. Choose the white star layer; the
stars should be highlighted
C. In the layer tool, choose the
blue star field layer; this will
place the highlighted geometry
(in this case, the stars) in the
blue star field layer
a. The stars are not cutouts
of the blue layer
B

C
Lesson 5 - Image Import

Importing Color Images

Step 5: Nest the Parts Again

A. Go to CAM
B. Follow the steps previously
executed for Nesting
a. Notice how the stars
are no longer individual
parts, but cutouts in the
star field layer
 Lesson 6:
Fabrication Heads & Cut Charts
Lesson 6 - Fabrication Heads & Cut Charts

Adding a Fab Head ● Fabrication Heads are

the actual cutting heads
on your machine
● Plasma, Water Jet, Oxy
Fuel, Router, Marker,
Laser, and/or Laser
Pointer
● Some types of fab heads
have associated Cut
Charts with cutting
parameters such as
feedrate, kerf width, and
cut height; which vary for
a given type and
thickness of material
Lesson 6 - Fabrication Heads & Cut Charts

Adding a Fab Head

A. Click the Gears icon
A
located at the top right
corner of the window
a. The Configuration
Screen will pop up
B. Go to the Fabrication
Heads section
B C C. Select a New Fab Head
Lesson 6 - Fabrication Heads & Cut Charts

Adding a Plasma Fab Head

E
A. Choose the Type, SubType, and Model from the dropdown
A
menus; ID and Name will be automatically populated
B. Set X/Y Offset if you have more than one fab head
C. Select RS-232/485 and a COM Port if you have direct
communication to set the torch’s current and pressure
D. Fill in the proper Output Lines for turning the Torch On and
Off as well as the correct macros for Automatic Execution B
Mode
E. Hit the Add Fab Head button to finalize your fab head
changes
F. Save the Setup file
D
Lesson 6 - Fabrication Heads & Cut Charts

Adding a Plasma Fab Head (THC)

A
B
C
D
E

If you have Torch Height Control, check the box and fill in the parameters:
A. Arc Voltage Divisor – This is typically 50 and must match the exact voltage divider setting in your torch. For
THC to work properly: (Maximum Raw Voltage Arc Voltage Divisor) must be < 6V.
B. Lock Out Factor – THC will suspend to prevent unwanted diving when the XY velocity of the torch is below
this percentage of the feedrate
C. Lock Out Hysteresis – THC will resume when the XY velocity goes above: (Lock Out Factor + Lock Out
Hysteresis) * Programmed Feedrate
D. Set Point Offset – Offsets the small idle voltage when torch is not in use
E. Sensitivity & Deadband Voltage – This is a factor that determines how quickly the THC acts towards voltage
fluctuation. This number can vary from 0.09V-1.94V, smaller values being more sensitive
Lesson 6 - Fabrication Heads & Cut Charts

Adding a Plasma Fab Head (Sensing)

Sensing will allow the torch to find the surface of the plate
A. Choose the sensing Direction and Feedrate
B. Choose the Monitor Input Line for the Primary Sensor, typically an Ohmic sensor
C. Sensor Offset is the extra distance that the Z axis travels between zero and tripping the sensor
D. Use Additional Sensor enables a backup switch in case the primary touch off method fails; this is
typically a mechanical switch or proximity sensor
E. Program Zero Sensing enables the torch to set program zero at the sheet
F. Retract Distance is amount that the torch will raise after sensing

B
C
D

E
F
Lesson 6 - Fabrication Heads & Cut Charts

Adding a Plasma Fab Head (Cont.)

A. Safe Height will raise the torch to a
specified height after every cut A
a. This height can be in Program
or Machine Coordinates
B. Touch Off causes the torch to sense
B
the plate before every cut
C. If Zero Life Axis Program Coord in C
enabled, each tough off will also zero D
the Z axis program coordinate E
D. Rapid Move to Start Height will cause
the Z axis to rapid down to a specified
height before beginning the sensing The radius is specified in the CNC panel at run time
procedure while touching off
E. If Enable Suppression Radius is
checked, the torch will skip all touch
off procedures within a specified
radius of the previous touch off
location
Lesson 6 - Fabrication Heads & Cut Charts

Advanced Plasma Control

Cut leadin when returning to toolpath (found under Cutting when customizing a new
fab head) – Designed for recovering from a lost torch using the following steps:
A. Use jump to line and the run forward, backward, and feedhold
controls in Dry Run mode to the point the cut stopped
a. Dry Run mode can be toggled in CNC on the left panel
B. Jog off of the toolpath to a point that will be off the finished part
C. Disable Dry Run mode and start the program from that point
D. The system will use that point as a temporary pierce position
and then cut a lead-in to the last feedhold position on the part
E. The program will proceed normally from that point
Lesson 6 - Fabrication Heads & Cut Charts

Cut Charts
A. Many of the Plasma and Oxy Fuel fab heads have pre-loaded cut charts with
manufacturer-recommended cut parameters
B. You can use the Standard Cut Charts for the fab head manufacturer’s recommended settings
C. If you choose the Custom Cut Chart option, then the standard cut charts will be stored to the specified
location as several CSV file copies when you hit the Copy Standard Charts To Folder button
D. Any value in these cut charts can be edited using a spreadsheet program such as Excel
E. Feedrates and pierce times for waterjet are calculated from a formula embedded in the software
Lesson 6 - Fabrication Heads & Cut Charts

Adding a Laser Pointer

A. Go to Fabrication Heads in the Configuration Screen and select New Fab Head
Lesson 6 - Fabrication Heads & Cut Charts

Adding a Laser Pointer

E A. Choose the Type Laser Pointer

B. ID and Name will be automatically populated
A C. Set X/Y Offset as the distance from the
center of the laser pointer to the center of the
B main fab head
D. Fill in the proper Output Lines for turning the
C Torch On and Off as well as the correct
macros for Automatic Execution Mode
E. Hit the Add Fab Head button to finalize your
D fab head changes
F. Save the Setup file
 Lesson 7:
Advanced CADCAM Tools
Lesson 7 – Advanced CADCAM Tools

Using the Text Tool

A. Choose starting point with your
mouse or type the XY Positions
B. Type the text you want
C. Choose a font; once you choose an
A-D
initial font, you can use the up/down
arrows to scroll through and view
other fonts
D. Adjust the size, kerning, line spacing,
angle, bold, and italic options
E. Check it in

E
Lesson 7 – Advanced CADCAM Tools

Using Advanced Text Toolpath

A. Go to the CAM mode by selecting the

double arrows A
B. Note that the toolpath is created
without the need to explode the text
(unless you need to modify the
geometry of the text such as adding
bridges)
C. You can move and change the lead-in
of each letter, which will be retained
even if another letter in the word is
edited
Lesson 7 – Advanced CADCAM Tools

Editing Text Without Explode

A
A. Return to the CAD module
B. Click on the text to open the
C
object’s parameters panel for
editing, even after generating a
B
tool path
C. Change one letter in the word
you typed
D. Check in any changes

D
Lesson 7 – Advanced CADCAM Tools

Toolpath of New Text

A. Go to the CAM module
a. Notice how the toolpath
regenerated with the new
text from the font without
having to explode the font
Lesson 7 – Advanced CADCAM Tools

Using the Fix Tool

A. Go back to CAD
B. Click Line Tool
A C. Draw box around the text, but
leave the last line disconnected
B from the first; this is easier to do
if you deactivate all of the
snapping tools

C
Lesson 7 – Advanced CADCAM Tools

Create the Toolpath

A. Go to the CAM module by hitting the double arrows
B. The toolpath for the rectangle did not appear because it is not a closed entity
C. If you choose the Make Top Level Features a Cutout button, the rectangle will
appear but the text will become a cutout and not a part
D. Switch back to Make the Top Level a Part feature type

B C
Lesson 7 – Advanced CADCAM Tools

“Fix” the Rectangle

A. Go back to the CAD tab
B. Click the Fix Drawing tool
C. Choose a tolerance larger than any
A of your drawing errors
B
C D. Hit the Search Issues button
E. Any issues found will be noted with
a green circle; any issues that
cannot be fixed automatically will be
noted with a red circle
D&F F. You can either choose the Fix All
button to automatically fix the issue
E of fix them manually
Lesson 7 – Advanced CADCAM Tools

Create the Toolpath

A. Go to CAM by clicking on the
double arrows
a. Note that the “fixed”
rectangle now appears no
matter which feature type is
the top level
Lesson 7 – Advanced CADCAM Tools

Using the Measure Tool

A. Go to CAD
A B. Click Measure Entities with
Ruler tool
C. Select the mode you want:
Points, Entities, or Protractor
B
D. Select the portion of the
C drawing you want to
E measure
D E. The corresponding
dimensions will appear in the
right side as well as on the
drawing
Lesson 7 – Advanced CADCAM Tools

Using Bridges
D A. Go to CAD
A B. Draw the text “BOA”
surrounded by a rectangle
C. If you cut this, the centers
B (shaded in blue for
illustration) would fall out
D. Select the text and use the
Explode button so that it
becomes line segments
Lesson 7 – Advanced CADCAM Tools

Bridge Interior Features

A. Choose the Bridge tool
B. Draw bridges to join the
interior of the letters to the
surrounding box
D C. Finalize each bridge by
hitting the green Check or
A starting a new bridge
D. You can set the width of each
B bridge individually and you
can move the bridge with
your mouse before it is
finalized

C
Lesson 7 – Advanced CADCAM Tools

Create Corner Loops

A

Corner looping minimizes dross on

sharp, exterior corners

B A. Hit the double arrow to go to

CAM mode
B. Go to Plasma Settings and set
Corners to Round or
Triangular Loops
B C. Set the Corner Extension
Distance; for example 0.15 in
D. Hit the green Check and save
C
the CADCAM file
Lesson 7 – Advanced CADCAM Tools

Nesting Multiple Files

You are not restricted to only nesting

the parts in a given CADCAM file;
you can reference external CADCAM
B
A and DXF files as well

A. Select the Material Settings

icon
B. Specify the size and material
properties of the sheet you will
be cutting; in this example, we
will use a 48” x 24” mild steel
plate
Lesson 7 – Advanced CADCAM Tools

Nesting Multiple Files

A. Choose the Import External
Files icon
B. Choose the files that you want
B.1 to import and then hit the
A green Check for each one

B.2

In this case, we are nesting all the files

made in the different lessons

B.3
B.4
Lesson 7 – Advanced CADCAM Tools

Nesting Multiple Files

A
A. Select the True-Shape
Nesting icon
B. On the right will be a list of the
parts to nest; click on each
name and change each count
C. Note that the named part gets
highlight in blue when name is B
clicked
D. Check Automatically Add D
Workpieces if you need more
than 1 sheet
E. Fill in the other options such F
as nesting direction, minimum
distances, etc
F. When you are ready, hit the
Start Nesting button; complex
nests will take longer
Lesson 7 – Advanced CADCAM Tools

Nesting Report
A. Click on the Nesting Report
tool to open information about
the nest
a. Information includes
number and type of A C
parts and material
efficiency B
B. Toggle the Part Numbers
CAM view to see an overlay of
the name of each part in the
nest
C. Adjust the material price/lb to
receive financial information
Lesson 7 – Advanced CADCAM Tools

Send Nest to CNC

A. Select the sheet that you want

to cut
B. Select the double arrow
between CAM and CNC

The G-Code of the nested toolpath

will be sent automatically to CNC
 Lesson 8:
More Advanced CAD Tools
Lesson 8 – More Advanced CAD Tools

Elliptical Arc

A. In CAD, choose the Elliptical

Arc tool
B-D B. Chose the center point for the
A
full ellipse with your mouse or
by typing on the parameters
panel
C. Choose the major and minor
radii of the ellipse
D. Choose the start angle and
end angle with your mouse or
by typing on the right
E. Draw the upper arc only
F F. Hit the green Check
Lesson 8 – More Advanced CAD Tools

Mirroring
A

A. Select the Mirror tool

B. Check the Copy Object box –
otherwise, the original copy
will be removed
B
C. Select the elliptical arc to
C mirror and right click to accept
D. Select the left end of the
elliptical arc as one endpoint
of the mirror line
D E E. Select the other endpoint of
F the mirror line; while you
select, the mirror line is dotted
F. The mirrored object will now
appear
Lesson 8 – More Advanced CAD Tools

Curved Text

A. Use the Text tool to type the

text to curve in any font and
size
B. Select the Curved Text tool
A B
C. Select the text that you want
to curve then right click to
D confirm
C D. Select the curve that you want
the text to follow and right
click to confirm
Lesson 8 – More Advanced CAD Tools

Curved Text
A. Adjust the parameters to
flip the text; determine the
alignment and offset

In this case, we want the bottom

of the text to be just below the top
of the curve
A

B. Use the arrows next to the

B text to move the text along
the curve

Note: You can still edit the text in

the text editor
Lesson 8 – More Advanced CAD Tools

Shape Welding

A. Explode the text into

geometry by selecting the
text and hitting the Explode
C button
A B. Select all of the geometry
that you want to weld
together; in this case, it’s all
B of the geometry so you can
use ctrl+A or drag over the
part to select everything
C. Choose the Weld Selected
Entities tool to weld
everything into one part
Lesson 8 – More Advanced CAD Tools

Linear Pattern
C. 1

A. Draw a long horizontal

rectangle and a short
C. 2 vertical rectangle on the left
(see red rectangle in image)
B. Select the red rectangle by
alt+clicking any of its sides
C. Click the Linear Pattern tool
and enter the spacing and
A count parameters

Note that there is also a Circular

Pattern tool
Lesson 8 – More Advanced CAD Tools

Welding and Boolean Operations

A

A. Select the Weld Entities tool

to weld the objects together
once you are happy with the
lace pattern

Note: The Boolean Operations tool

allows you to do welding and other
operations such as subtracting
entities and welding cutouts
Lesson 8 – More Advanced CAD Tools

Create the Toolpath

A. Hit the double arrow button

to automatically create a
A B toolpath
B. Hit the next double arrow
icon to generate a G-Code
and send it to the CNC
panel
Lesson 9:
Pipe Tools
Lesson 9 – Pipe Tools

Start New Pipe Drawing

A

A. Under the File menu choose

“New”
B. Choose “Pipe Part”

B
Lesson 9 – Pipe Tools

Choose Pipe Size and Geometry

A

A. Choose the “Pipe Profile

Definition” icon
B. Fill in the appropriate pipe
B dimensions for length, outer
diameter (OD), and wall
thickness and check it in

Notice how the Pipe OD and wall

thickness can be based on ASTM
standards
Lesson 9 – Pipe Tools

A. Choose the Pipe Joint Shape tool

Determine Mating Conditions B. Determine the shape of the joint
A you are creating – Branch,
Header, Miter, End Cap, Wye, or
B
Through Pipe

In this case, the pipe is a 4” branch

mating with a header on the left side at
90 deg.
C+D
C. Fill in the appropriate dimensions
of the mating pipe and which side
it is mating with
D. Determine any extra clearance for
welding etc.
E E. Preview both part and mating part
F
with disassembly tool
F. Check it in once satisfied
Lesson 9 – Pipe Tools

New Geometry is Created

Note:
● The shape tool just created new
geometry on the original chosen
pipe
● An unwrapped 2D view on the
left and a solid 3D view on the
right are shown
Lesson 9 – Pipe Tools

Add the Other Shape Parameters

A
B. 1 A. Choose the Pipe Joint Shape
tool again
B. Determine the shape of the
joint you are creating

In this case, we will make the right

B. 2 side of a 4” pipe mating at 45 deg.

C. Check it in

B. 3
Lesson 9 – Pipe Tools

Draw more Features in 2D Window

A. Draw a rectangle in the 2D
unwrapped view

Notice how it becomes a slot in the 3D.

B. Draw a circle
C. Draw any shape you want

A Note that Text needs to be exploded.

The Bridge tool and Boolean tools also
work in pipe mode.
B
Lesson 9 – Pipe Tools

Send the Pipe to CAM

A A. Choose the double arrows or the
CAM button
A toolpath is created with using the
original pipe dimensions

The red denotes the main toolpath. The

gray is a shadow view of the same
toolpath.

Note: The lead-ins, lead-outs can be

manipulated identically to how they are
edited in 2D
Lesson 9 – Pipe Tools

Enter the Length of the Stock Pipe

A. Change the pipe length in

CAM to 30”
Lesson 9 – Pipe Tools

Nest the Pipe

A

A. Choose the Pipe

B Nesting Icon
B. Change the Count to 3
C C. Hit the Start Nesting
button

Notice how the parts flipped

and staggered to create an
efficient Pipe Nest

D. Check it in

D
Lesson 9 – Pipe Tools

Send the Pipe to CNC for Cutting A. Make sure your

configuration is properly
B
set for rotary pipe
cutting
B. Hit the double arrows to
create the G-Code and
C
send the toolpath to
CNC
C. Set the surface of the
D part to the radius of the
pipe
D. Make sure the Cut
Height, Pierce Height
and Safe Height are
properly set
E. Run the part

E
Lesson 10:
Smart360TM
Lesson 10 – Smart360TM

Enable and Configure Parameters

A. Make sure you have a compatible torch
configured
B. Open Plasma Settings in the CAM
module
C. Check the “Enable Smart360TM” toggle
D. Enter the size of the holes you want to
apply Smart360TM to, based on the
sheet thickness
E. Change the feedrate reduction factor as
desired (default is 18%)

If the selected parameters are compatible, an

Additional Kerf value will be generated.
D-E Otherwise, the user can enter a value based
on experience
Lesson 10 – Smart360TM

Modify Lead-In
A. Open the Breaks tool to change lead-in
parameters

A Each aspect of the Smart360TM lead-in is

generated automatically
B
B. For advanced users, each parameter
can be individually modified
 Lesson 11:
Cutting a Part in CNC
Lesson 11 – Cutting a Part in CNC

Activating Controller License

A. Make sure the controller is connected
by selecting the Connect Button
B. Agree to the “Safety First” message
and hit OK to upgrade the firmware
C. If you configured homing, selecting
C the Home All; the machine will seek
A the switched on all axes and set all of
the Machine Coordinates to 0
Lesson 11 – Cutting a Part in CNC

Set your Program to Zero

A. Jog to the zero point of your program
B by clicking on any of the jog buttons
either in Continuous mode or any of
the discrete distances; the slider bar
determines speed
B. Set the X & Y Program Coordinates to
zero with the Set button and Zero X
and Y
C. If you have a sensor on your Z axis,
set your Z axis coordinate by clicking
Set and Sense Z Zero; if you don’t
have one, select New… under Set to
set your coordinates
Lesson 11 – Cutting a Part in CNC

Cut the Part

A. Verify the toolpath by clicking Dry
Run and then the green Run
G-Code button
B. If everything looks good, you can
move back to program zero by
switching from Job Mode to Point
A Mode and selecting the green
B Program Zero button
C
C. To cut the part, uncheck Dry Run
and select the green Run G-Code
button
D. You can stop the program at any
time by choosing the red Feed
Hold button
D
Lesson 11 – Cutting a Part in CNC

Program Flow Control

A. The Run G-Code buttons runs the
program forward and cuts the
parts
B. The red Feed Hold button ramps
down the motors and stops the
program
C. The gray Run G-Code in Reverse
button will run backwards, but
won’t cut
D. You can speed up or slow down
C B A the feedrate in real-time by hitting
D
the + or - feedrate buttons
Lesson 11 – Cutting a Part in CNC

Jump to Line
A. Jump to any line of the program
while idle by pressing the Jump to
Line button
B. You can now select any line in the
Program Listing Boc or any
command in the Viewport
C. Click the Execute Jump To Line
button
D. A dialog will pop up verifying the
D
Jump to Line was Completed;
choose Yes to move the machine
A
to the beginning of the line
C
You can run the program forward or
B backwards using normal program flow
control
Lesson 11 – Cutting a Part in CNC

Progress Meter

Automatically calculate program runtime

A. The value on the left shows total

runtime
B. The value on the right shows time
remaining
C. The meter fills as the program
runs to visually indicate progress
A C B
Lesson 11 – Cutting a Part in CNC

Advanced Oxy Fuel Control

Dynamically release oxy fuel during

A preheat process

A. Choose to overwrite the delay with

the current time
 Lesson 12:
Diagnostics & Help
Lesson 12 – Diagnostics & Help

Diagnostics & Help

A. The System Status panel is
C accessible through the Magnifying
glass icon
B. Live status of Input Lines is shown
A by the switch icons and blue LEDs
(only active if the software is
connected to the controller)
C. Live status of the Output Lines are
also available; turn any output on
and off simply by clicking on its
button

B
Lesson 12 – Diagnostics & Help

THC History
A A. Click the THC DATA tab to view
recorded cut data
C B. Data is organized by runs; all
saved runs can be seen in the top
dropdown
C. The top chart displays torch
C height; the middle shows the
set-point and measured voltages;
the bottom shows THC state,
according to the legend
C D. The scroll wheel can be used to
zoom; right-click and drag will pan
Lesson 12 – Diagnostics & Help

Help Screen and User’s Guide A. The Help screen can be

accessed by clicking on the ?
button

This shows the serial number as well

as current software and firmware
A versions

B. Build Support File will create a

ZIP with configuration settings
and a log of past commands;
B this can be emailed to our
support staff for in-depth
diagnostics

Any online manuals are available

through the Help window in some
versions
Lesson 12 – Diagnostics & Help

User’s Guide

A. The User’s Guide will launch on

the computer’s default PDF
A application
B B. Clicking on any of the sections in
the Table of Contents will bring
the user to the chosen page
C. The Find function can be used to
locate relevant information
Lesson 12 – Diagnostics & Help

Five Languages Supported

A. To change a language go to Configuration and select Language
B. Choose the language you need from the drop down menu
C. You will need to save the configuration, exit, and re-enter the program for the language you register

Note: Only the software will be changed; all manuals are in English
C ● English
● Spanish
● Italian
● French
● Portuguese
A B
● German
● Japanese
● Dutch
Contact Information

● Phone: (847) 940-9305

● Email:
○ [email protected]
○ [email protected]
● Website: www.flashcutcnc.com