Fusion Simultaneous 5-Axis Post Processor
Continuous 5-axis motion is where posts are really tested. We build Fusion posts that deliver smooth, safe simultaneous 5-axis output: TCP, singularity handling, rotary preferences, correct feedrates, linearisation and clean retracts at axis limits.
Smooth motion through every orientation
In simultaneous 5-axis machining, such as swarf cutting, multi-axis contour, flow and blade or impeller finishing, all five axes move together. Problems that never appear in 3+2 work suddenly matter: the machine flipping through a singularity, rotary axes choosing the wrong solution, feedrate spikes when the rotary axes move quickly, linear axes deviating from the programmed path between points, and rotary limits reached mid-cut.
ENGIMANDI builds simultaneous 5-axis posts that manage these issues. We use controller TCP where available, configure solution preferences and singularity tolerances, choose the right feed mode (inverse time or controller-managed), linearise moves when needed, and handle retract, rewind and re-entry when an axis runs out of travel. We then verify with Fusion's machine simulation and careful proving at the machine.
Read simultaneous 5-axis post processors and 3+2 vs simultaneous 5-axis.
What you get
- TCP / RTCP output
- Singularity handling
- Rotary solution preferences
- Inverse time feed control
- Linearisation
- Axis limit retract & rewind
- Machine simulation
- Proving on complex parts
Simultaneous 5-axis details we handle
The difference between smooth and scrap.
Tool Centre Point
Controller TCP keeps the tool tip on the path while rotary axes move.
Singularities
Controlled behaviour near the rotary pole to avoid sudden flips.
Solution Choice
Preferred rotary solutions for reach, stiffness and collision avoidance.
Feedrate Control
Inverse time or controller feed modes for consistent cutting speed.
Linearisation
Extra points inserted where rotary motion would deviate from the path.
Limit Handling
Safe retract, rewind and re-entry when an axis reaches travel limits.
Simultaneous 5-axis stack
Post engine and controller functions.
Typical projects
- Impeller and blisk finishing
- Swarf cutting of turbine blades
- Medical implants and orthopaedic parts
- Aerospace structural walls and pockets
- Port and manifold finishing
- Mould cores with steep walls
How we build simultaneous posts
Model
Exact machine kinematics.
Develop
Continuous motion logic.
Stress-test
Hard toolpaths near limits and poles.
Simulate
Full Fusion machine simulation.
Prove
Step-by-step machine trials.
Simultaneous 5-axis questions
Why does our machine flip suddenly during a cut?
The toolpath is passing near a singularity or the post is switching rotary solutions. We adjust preferences and singularity handling to avoid it.
Do we need controller TCP?
It is strongly recommended for simultaneous work. Without TCP, the post can calculate positions, but programs depend on exact fixture and pivot data.
Why do feedrates vary during 5-axis moves?
Rotary motion changes the actual tool speed. Inverse time feed or controller features keep it consistent.
What happens when an axis hits its limit?
The post retracts, rewinds the axis and re-enters safely, following rules you approve.
Can you test with our hardest parts?
Yes. We use your most demanding toolpaths as part of testing.