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Millbox has two versions to verify the output file for mills. There is now a lightweight visual simulation version, referenced as the Show Residual Material simulation, to help detect if screw holes, cavities, or finishing tool path calculations have been created. The advance simulation, also referenced as the Kinematic Simulation, is also available to simulate the toolpaths and verify the final geometry.
Simulation Menu Options
There are two options that can appear after a calculation is completed. Show residual material option will only show if users select calculate simulation or have it set as default to calculate the residual automatically. If the show residual material calculation is not performed, then the Kinematic simulation will appear automatically once clicking the Simulation button.
Show Residual Material Menu - Fast In-app Visual Simulation Tool
This option appears if the simulation is automatically or selected to also calculate while calculating the tool paths in the Start Mill menu.
This visualization simulation tool uses a color marking visualization to show where material is present or not relative to the original STL design while in Millbox.
Residual Heat Map
- Color legend for simulation remaining thickness indications
- Show only the milling simulation visuals to show remaining material difference.
- Show only the 3D visualization of unit to be milled.
- Show both item 2 and 3 models together.
Interpreting the Residual Material Color Map
The visualization shown is a comparison of the finished material removal to the original unit. This will help quickly identify any potential issues with of missing toolpaths or areas where detail may not be able to be replicated due to the tool diameter.
In the image shown above, you can see that there is some green in the occlusal anatomy. This is identifying that the milling simulation would not mill the original design and there would be up to 0.2mm of material remaining. The color visualization around the sprues also show that extra material will remain as this strategy used in this example only uses the 1mm near that area to finish next to the sprue.
If you see large red or blue spots on the model, likely a tool operation was not calculated. There are many potential root causes for these errors that we are not able to go through in this article.
Kinematic Simulation Menu - Advanced Toolpath Simulation Tool
This menu will open the tool path simulation application that will allow you to see the simulated toolpaths and material removal. This is much slower and more computationally intensive than the Residual Material simulation. This will visualize the action of the various tools cutting the material step by step to show the final output simulation. This allows for more granular and clearer visualization to see if there are any errors. Simulations will not show if a unit will or will not chip.