Import relief models for rotary machining in Vectric | Wrapped Rotary Machining

Overview

This tutorial demonstrates how to import a flat 3D relief model into a Vectric Aspire rotary machining session, wrap it onto a cylinder, and create toolpaths. It covers file setup, model import/scaling, the importance of a modeling plane, adding decorative coves, and generating a 3D roughing and finishing toolpath.

Steps

1. Create a new rotary job:

   • Set length to 12 inches, diameter to 4 inches, units in inches.
   • Set Z0 position to the cylinder axis.
   • Set XY datum to bottom-left.
   • Set orientation along the X-axis (wrapping the Y-axis).
   • Set modeling resolution to “Very High” and click OK.

2. Import the 3D model:

   • Go to “Import a component or 3D model” and select the floraldrop.stl file.
   • The model is imported as a full 3D model initially – change orientation to “Top”.
   • Rotate the model 90° so it sits along the X-axis.
   • Scale the model to 9 inches in X with the lock ratio enabled so Y and Z scale proportionally.

3. Add the modeling plane:

   • When prompted, confirm adding a modeling plane (click “Yes”).
   • This prevents distortion when the model is wrapped around the cylinder.

4. Verify model position:

   • Open the toolpath menu → “Job Setup”.
   • Check “Model Position in Material”: model thickness 0.5 + modeling plane 1.5 = 2.0 inches (half the cylinder diameter).
   • Keep the model position slider at the top.

5. Add coves around top and bottom edges:

   • In the 3D view, unwrap the view.
   • Switch to the Design tab and use the polyline tool.
   • Click near X = 0.5, then snap to the bottom edge.
   • Press Ctrl+Shift+H to duplicate the line on the opposite side.

6. Create the 3D roughing toolpath:

   • Go to the Toolpath menu → “3D Roughing Toolpath”.
   • Use model boundary, a 1/4“ end mill, and leave a machining allowance for finishing.
   • Use Z-level strategy, then click Calculate.
   • Preview the toolpath to verify material removal.

7. Create the 3D finishing toolpath:

   • Go to “3D Finishing Toolpath”.
   • Use an 1/8“ ball nose.
   • Use model boundary and raster strategy with 0° angle.
   • Click Calculate and preview the result.

Key Points / Warnings

• Double-check the rotary axis orientation for your specific machine setup.
• A modeling plane is essential – without it, the wrapped model becomes badly distorted.
• The model thickness plus modeling plane must equal half the cylinder diameter (2 inches for a 4-inch diameter).
• Raster angle 0° cuts along X with incremental rotation; 90° rotates continuously around the cylinder.
• The toolpath preview first unwraps the job, runs the 3-axis toolpath, then rewraps it for display.
• Tool settings edited via the “Edit” button apply only to the current toolpath; changes made through the tool database button are permanent.
• Always verify rapid Z-gap and safe Z settings for your own rotary setup.