PathForger – Cross Platform Toolpath Generation Software

Modern robotic manufacturing often requires engineers to manually program robot movements for each robot brand—a process that is time-consuming, highly specialised, and prone to human error. To overcome this, A*STAR IHPC developed a modular, brand-agnostic software framework that automatically converts CAD models into ready-to-use robot motion commands.

The software processes surfaces or parts from a computer-aided design (CAD) file and generates a continuous, optimised toolpath tailored to the user’s process needs. It then translates these waypoints into the selected robotic language—such as RAPID, Lua, or G-code—fully removing the need for manual, brand-specific programming and enabling users to focus on process performance rather than code writing.

The codes generated by the software have been tested and validated on real robotic arms at A*STAR Institute of Materials Research and Engineering (A*STAR IMRE) and A*STAR Advanced Remanufacturing and Technology Centre (A*STAR ARTC), demonstrating strong robustness, reliability, and compatibility with actual industrial platform.

With its intuitive interface, guided workflow, and automated routines, the software enables even non-experts to generate complex robotic paths within minutes, making the transition from digital design to physical robot execution seamless, efficient, and error-free.

Features

End-to-end automated toolpath generation: Automatically converts CAD surfaces into a continuous, optimised single-line toolpath that can handle complex 2D geometries—including non-convex, multi-connected, and multi-domain shapes—without manual intervention.
Multi-brand robotic code translator: Instantly transforms generated waypoints into multiple robotic programming languages, removing the need for brand-specific coding and reducing programming errors.
Customisable process parameters: Allows users to easily set key process parameters such as standoff distance, tool angle, step size, and overlap, ensuring consistent performance and high-quality outcomes across different applications.
Modular and extensible architecture: Designed for long-term scalability, enabling seamless addition of new robot brands, processes, or toolpath logic as manufacturing requirements evolve.
User-friendly workflow: Features a clean graphical user interface (GUI), guided step-by-step interactions, and built-in validation checks to reduce the learning curve and streamline the entire toolpath-to-robot trajectory workflow.
Multi-OS support: Fully compatible with major operating systems—including Windows, macOS, and Linux—providing users with flexibility in deployment and integration.

The Science Behind

Although the software looks simple on the surface, it works by combining a few smart techniques that help turn a CAD file into real robot movements.

Mechanism- and physics-driven toolpath planning: Cold spray works differently from other additive manufacturing processes, so creating an effective toolpath requires strong understanding of the physics and underlying mechanisms pertaining to how particles move, adhere, and build up material for high-quality part formation. To enable this, we have developed a comprehensive multi-physics and multi-scale simulation platform that accelerates technology development in this area.
Understanding the shape: The software breaks down the CAD model into thin layers and then draws a single continuous line that covers each layer smoothly. This creates a clean and efficient path that the robot can follow, even for shapes that are curved or complicated.
Turning the path into robot commands: Every robot brand speaks its own “language.” The software takes the generated path—stored as plain coordinates—and converts it into the exact commands that each robot brand requires. This ensures that the final code is correct and ready to run on the robot without manual fixing.

Industry Applications

This technology can be applied across industries where robots must follow precise and repetitive paths on complex surfaces, such as:

Aerospace: repair, coating, inspection, and cold spray additive manufacturing.
Advanced manufacturing: automated polishing, finishing, machining, and quality inspection.
Automotive: spray applications, sealing, adhesive dispensing, and surface finishing.
General robotics integration: any workflow that benefits from rapid, no-code robot programming.

By enabling fast, automated, and brand-agnostic toolpath programming, this software reduces manpower needs, shortens development time, and improves overall process reliability.

Manufacturing & Engineering

PathForger – Cross Platform Toolpath Generation Software

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