FoamNester is a desktop CAD/CAM tool built specifically for hot-wire and CNC foam cutting. It takes the parts you need to cut, arranges them efficiently on your foam block, and produces clean, machine-ready g-code — without a steep learning curve.
Why we built it
Existing nesting software is often built for sheet metal or large industrial CNC, and rarely understands the realities of wire cutting: kerf from the wire, lead-ins and lead-outs, parting cuts, and cutting from odd-shaped leftover blocks. FoamNester focuses on exactly those needs so you spend less time fighting the software and more time cutting.
Made for real workshops
From hobbyists cutting foam letters, models and props to industrial workshops producing cornices, packaging inserts and architectural foam, FoamNester is designed to reduce waste and get parts off the machine faster. From simple 2D shapes to dovetail strip joins, it covers the full range of wire and hot-wire cutting work.
What it does
- Nesting — packs irregular parts with rotation and configurable spacing.
- DXF import — bring in drawings and edit them as chained paths.
- Cut-line tools — vertical, horizontal, chop and U-parting cuts with full direction and ordering control.
- Kerf compensation — per-part offsets with fixed edges for accurate finished sizes.
- Custom blocks — nest onto stepped leftover foam, not just plain rectangles.
- G-code export — post-processors for Mach3/4, LinuxCNC, GRBL, UCCNC, Smoothieware and FluidNC.
Built to run anywhere
Runs on your machine
Nesting happens locally on your own computer — no upload, no waiting on a server, works offline. Your license is checked online periodically, with a 7-day grace period so the app keeps running offline between checks.
Fast & interactive
A responsive canvas lets you drag, rotate and fine-tune every part and cut line.
Machine-ready output
Export g-code tuned to your controller, ready to load and cut.
Actively developed
New tools and post-processors are added regularly based on real user feedback.