A morph is a cut where the two ends of the wire follow different profiles. As the machine moves, the straight wire blends smoothly from the left (X/Y) profile to the right (U/V) profile, sweeping a ruled surface between them. This is how a single pass cuts a shape that changes cross-section along its length.
What morphing can make
- Tapered wings — a fat aerofoil at the root blending to a thin one at the tip.
- Transition ducts — square at one end, round at the other.
- Tapered columns & finials — different cross-sections each end.
- Twisted forms — by rotating one profile relative to the other.
Loading a morph
In ＋ Load parts, pick Two-part morph and choose a file for Profile A (left) and Profile B (right). You need a 4- or 5-axis machine type. The cut length along the wire-spacing axis comes from your material block Z size.
Smart-sync alignment
For the morph to look right, point 1 on profile A should connect to a sensible point on profile B — otherwise the surface twists unintentionally. cncfoam.com smart-syncs the two profiles: it rotates profile B so the wire spans the shortest total distance, lining up corresponding points and minimising wasted wire travel. It also picks a lead-in point near the origin to avoid undercuts.
Adding twist
Use the Object bar's Rotate UV field to twist profile B relative to A. A constant twist along the length gives a helical/spiral cut; combine it with a taper for washout in a wing.
The cut-speed mismatch warning
The two profiles can have very different perimeters. Because both wire ends must arrive at corresponding points at the same time, the end tracing the longer perimeter moves faster — and may exceed the melt speed, scorching that side. cncfoam.com warns when the left/right perimeters differ by more than about 1.5×.
It is still a ruled surface
Remember that even a morph can only ever be a ruled surface — every point on the finished face lies on a straight line between profile A and profile B. For doubly-curved 3D shapes you need to combine morphing with indexed rotation.