Case Study: Foamlinx achieves complex foam wingbox machining for Elytron with MecSoft VisualCAM

Foamlinx - Customer Case Study

Foamlinx, a company specializing in foam cutting and machining services, was faced with the complex challenge of producing a prototype wingbox for the unique Elytron aircraft. The part required intricate machining of a foam core to create deep internal ribs and complex contours, all while ensuring the surfaces were suitable for subsequent carbon lamination using low-cost techniques. MecSoft Corporation's VisualCAM software was used to create the necessary toolpaths for this demanding project.

Using VisualCAM integrated within Geomagic Design, Foamlinx successfully programmed and machined the complex part on a 3-axis CNC router. The solution from MecSoft Corporation enabled the creation of a remarkably light 9-pound foam core that could withstand several thousand pounds of stress loads in flight. The final assembled and laminated wingbox weighed only 31 pounds, a result that was impressive for a part designed to withstand 100 times its weight in lifting forces, successfully fulfilling the requirements for this extraordinary outsourced job.

Foamlinx

Oliver Garrow

CTO & Co-Founder