3D CNC Tutorial | Curved Intarsia & Inlay Workflow (CAM + G-Code)
Download link for the Face to ZDepthCorrection macro: https://ko-fi.com/s/96e64a2bfa
After more than six months and over 50 FreeCAD CNC tutorials, this project celebrates the 1,000-subscriber milestone with something truly special: a 3D CNC intarsia and curved inlay project modeled and machined in FreeCAD CAM.
In this video, I take on one of the most challenging CAD-CAM workflows in FreeCAD: creating and machining 3D curved surfaces, pockets, and rounded edges using a combination of 3D Surface, Profile, Pocket, and Macro-based engraving operations.
The result is a parametric 3D project — from modeling, to toolpath generation and G-code export, all the way to CNC machining the final piece. This video also includes multiple FreeCAD CAM hacks, macro usage tips, and time-saving tricks for 3D surface finishing.
What You’ll Learn
How to model complex curved 3D shapes in FreeCAD Part Workbench
How to create intarsia-style curved inlays on a 3D surface
Tips for using macros to emulate advanced toolpaths in FreeCAD
Setting up multi-operation CAM jobs for 3D machining
How to optimize toolpaths for speed, finish, and tool safety
Exporting G-code and milling a full 3D project on the CNC
Want to understand the trick I used to make the toolpath follow the curvature of the top face?
Watch “Emulate 3D Surface Machining – FreeCAD CAM Tip 11” I show exactly how this macro-based hack works step by step: • Emulate 3D Surface Machining – FreeCAD CAM...
As FreeCAD 1.1 takes things to a whole new level, watch “3D Curved Engraving in FreeCAD 1.1 | Full CAD-CAM Machining Workflow” to see how the new version simplifies 3D surface operations and curved engraving with better control, optimized toolpaths, and downloadable macros: • 3D Curved Engraving in FreeCAD 1.1 | Full ...
00:00 3D CNC Intarsia & Curved Inlay Workflow in FreeCAD | Patreon Intro
01:00 Modeling Parametric Parts: Sphere & 3D Rectangle in FreeCAD Part Workbench
07:10 Creating a Curved Top Surface Using Intersection Tools
08:32 Parametric Design Test: Easily Adjusting Shape Dimensions
10:51 Designing a Smooth, Rounded 3D Rectangle with Curved Outline
17:07 Building the Intarsia 3D Curved Shape Parametrically
18:52 Modeling the Pocket for the Intarsia Insert
19:33 Testing Parametric Consistency in the 3D Model
21:04 Preparing SVG Files in Inkscape for CNC Inlay Design
22:44 Importing and Cleaning SVG Paths in FreeCAD
23:11 Adding Text and Aligning Placement for CNC Inlay
24:12 Combining Sketches and ShapeStrings for Inlay Geometry
26:43 Tip: Precisely Placing the Sketch on the Curved Surface
27:33 Cutting the Pocket for the Inlay with Extrude and Cut
28:40 Modeling the Negative Inlay Shape Using Boolean Union
30:07 Overview of CAM Operations: Pocket, 3D Surface, Profile & 3D Engraving
30:52 Creating the First CNC Job: Stock, Origin, and Tool Setup
32:32 Pocket Operation Setup & G-Code Generation
33:03 Adjusting Step-Down to Protect the Toolbit
33:42 Setting Up 3D Surface Operation for Curved Face Machining
35:02 Hack: Emulate a 3D Surface Toolpaths on Curved Faces
35:23 Creating a Projected Face for the MillFace Operation
36:25 Adding the Projected Face as Base Geometry for CAM
36:38 Generating MillFace Toolpath with Default Settings
37:05 Changing Boundaries, Angles & Depths for Optimal Results
38:21 Making Toolpaths Follow Curved Surfaces Using FreeCAD Macro
40:42 Creating a Roughing Pass for the 3D Surface
41:34 Duplicating and Refining Finishing Toolpaths
42:42 Applying the Macro for True Curved Surface Machining
42:38 Profile Operation Setup and G-Code Generation
44:00 Optimizing Step-Downs for Smooth Edge Milling
44:23 Trick to Round Curved Edges Using Profile Operation
44:52 Emulating Engraving Toolpath with “Use Compensation” Option
45:10 Adjusting Depths for a Single-Layer Pass
45:21 Setting Profile Operation for Edge Finishing Using a Roundover Bit
46:23 Using Macros for emulating 3D Engraving on Curved Surfaces in FreeCAD 0.21
48:31 Rounding Edges of the Intarsia Pocket with the Same Method
49:20 Duplicating Outline Cuts with Offsets for Clearance
50:14 Creating a New Job for the Intarsia Part | Stock & Tool Setup
51:01 Machining the Intarsia Curved Surface and Pocket
51:59 CNC Cutting the Intarsia Outline
52:13 Limitations of the Emulated Engraving Method
52:56 Creating a CNC Job for the Inlay | Rotating Model and Setting Stock
53:33 Pocket Operation for the Inlay with Base Support
53:51 Reducing Air Time for Efficient Toolpath Movements
54:12 Gluing, Assembly, and Final Finish of the 3D Project
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My Patreon page:
/ opensourcecnc
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