Maslow Brings The Wall Plotter Into The Woodshop

Hanging plotters, or two steppers controlling a dangling Sharpie marker on an XY plane, are nothing new to our community. But have you ever thought of trading out the Sharpie for a wood router bit and cutting through reasonably thick plywood sheets? That would give you a CNC machine capable of cutting out wood in essentially whatever dimensions you’d like, at reasonably low-cost. And that’s the idea behind [Bar]’s Maslow. It’s going to be a commercial product (we hope!), but it’s also entirely open source and indubitably DIYable.

[Bar] walks us through all of the design decisions in this video, which is a must-watch if you’re planning on building one of these yourself. Basically, [Bar] starts out like any of us would: waaaay over-engineering the thing. He starts out with a counterweight consisting of many bricks, heavy-duty roller chain, and the requisite ultra-beefy motors to haul that all around. At some point, he realized that there was actually very little sideways force placed on a sharp router bit turning very quickly. This freed up a lot of the design.

His current design only uses two bricks for counterweights, uses lighter chains, and seems to get the job done. There’s a bit of wobble in the pendulum, which he admits that he’s adjusted for in software. Motors with built-in encoders and gearing take care of positioning accurately. We haven’t dug deeply enough to see if there’s a mechanism to control the router’s plunge, which would be great to cut non-continuous lines, but first things first.

Taking the wall plotter into the woodshop is a brilliant idea, but we’re sure that there’s 99% perspiration in this design too. Thanks [Bar] for making it open! Best of luck with the Kickstarter. And thanks to [Darren] for the tip.

Making an Espresso Pot In the Machine Shop

[This Old Tony] was cleaning up his metal shop after his yearly flirtation with woodworking when he found himself hankering for a nice coffee. He was, however, completely without a coffee making apparatus. We imagine there was a hasty round of consulting with his inanimate friends [Optimus Prime] and [Stefan Gotteswinter Brush] before he decided the only logical option was to make his own.

So, he brought out two chunks of aluminum from somewhere in his shop, modeled up his plan in SolidWorks, and got to work.  It was designed to be a moka style espresso pot sized around both the size of stock he had, and three purchased parts: the gasket, funnel, and filter. The base and top were cut on a combination of lathe and mill. He had some good tips on working with deep thin walled parts. He also used his CNC to cut out some parts, like the lid and handle. The spout was interesting, as it was made by building up a glob of metal using a welder and then shaped afterward.

As usual the video is of [This Old Tony]’s exceptional quality. After quite a lot of work he rinsed out most of the metal chips and WD40, packed it with coffee, and put it on the stove. Success! It wasn’t long before the black stuff was bubbling into the top chamber ready for consumption.

Inventables Releases Improved X-Carve CNC Router

Introduced last year as an improvement on the very popular Shapeoko CNC router, the X-Carve by Inventables has grown to be a very well-respected machine in the community. It’s even better if you throw a DeWalt spindle on there, allowing you to cut almost everything that’s not steel. With a recent upgrade to the X-Carve, it’s even more capable, featuring the best mods and suggestions from the community that has grown up around this machine.

The newest iteration of the X-Carve features higher power drivers, better rigidity, and a heat sink for the spindle. That last item is an interesting bit of kit – routing takes time, and a 1¼HP motor will turn electricity into heat very effectively.

X-CarveIn addition to the 500mm square and 1000mmm square routers previously available, there’s a new, 750mm square machine available. All machines feature a new electronics box for the X-Carve, the X-Controller. This ‘brain box’ is a combined power supply, stepper driver, and motion controller built into a single box. The stepper drivers are able to supply 4A to a motor, is capable of 1/16 microstepping, and has connections for limit switches, spindle control speed, a Z probe, and outputs for vacuums or coolant systems. The underlying controller is based on grbl, making this brain box a very solid foundation for any 3-axis CNC build. The ‘brain box’ format seems to be the way the hobbyist CNC market is going, considering the whispers and rumors concerning Lulzbot selling their Taz6 brainbox independently from a 3D printer.

The new X-Carve is available now, with a fully-loaded 1000mm wide machine coming in at about $1400. That’s comparable to many other machines with the same volume, unlike the Chinese 3040 CNC machines, you don’t need to find an old laptop with a parallel port.

High-end Headphones Fixed with High-end CNC Machine

Warranty? We don’t need no stinking warranty! We’re hackers, and if you have access to a multi-million dollar CNC machine and 3D CAM software, you mill your own headphone replacement parts rather than accept a free handout from a manufacturer.

The headphones in question, Grado SR325s, are hand-built, high-end audiophile headphones, but [Huibert van Egmond] found that the gimbal holding the cups to the headband were loosening and falling out. He replicated the design of the original gimbal in CAM, generated the numeric code, and let his enormous Bridgeport milling machine loose on a big block of aluminum. The part was drilled and tapped on a small knee-mill, cut free from the backing material on a lathe, and bead-blasted to remove milling marks. A quick coat of spray paint – we’d have preferred powder coating or anodization – and the part was ready to go back on the headphones.

Sure, it’s overkill, but when you’ve got the tools, why not? And even a DIY CNC router could probably turn out a part like this – a lot slower, to be sure, but it’s still plausible.

Continue reading “High-end Headphones Fixed with High-end CNC Machine”

Impressive Junkyard CNC Made From Fancy Garbage

We’ll just come out and say it, [reboots] has friends with nice garbage. Sure, some of us have friends who are desperately trying to, “gift,” us a CRT monitor, hope dropping like a rock into their stomach when they realize they can’t escape the recycling fee.  [reboots] has friends who buy other people’s poorly thought out CNC projects and then gift him with the parts.

After dismantling the contraption he found himself with nice US and Japanese made linear motion components. However, he needed a CNC controller to drive it all. So he helped another friend clean out their garage and came away with a FlashCut CNC controller.

Now that he had a controller and the motion components whirring nicely, he really needed a frame to put it all in. We like to imagine that he was at a friend’s  barbeque having a beer. In one corner of the yard was an entire Boeing 747.  A mouldering scanning electron microscope with a tattered and faded blue tarp barely covering its delicate instrumentation sat in another corner. Countless tech treasures were scattered about in various states. It was then that he spotted a rusting gamma ray spectrometer in the corner that just happened to have the perfect, rigid, gantry frame for his CNC machine.

Of course, his friend obliged and gladly gave up the spectrometer. Now it was time to put all together. The gantry was set on a scavenged institutional door. The linear motion frames were bolted in place. Quite a few components had to be made, naturally, of scrap materials.

spindletest2Most people will start by using a handheld router for the spindle. The benefits are obvious: they’re inexpensive, easy to procure, and generally come with mounts. But, there are some definite downsides, one of the most glaring of which is the lack of true speed control.

Even routers that allow you to adjust the speed (a fairly common feature on new models) generally don’t actually regulate that speed. So, you end up with a handful of speed settings which aren’t even predictable under load. Furthermore, they usually rely on high RPMs to do their work. For those reasons, handheld woodworking routers aren’t the best choice for a mill that you intend to cut metal with.

[reboots] noticed this problem while building this machine and came up with an inexpensive way to build a speed-controlled spindle. His design uses a brushless DC motor, controlled through a hobby ESC (electronic speed control), which uses a belt to drive the spindle. The spindle itself is mounted using skateboard bearings, and ends in an E11 collet (suitable for light machining in aluminum).

With the ESC providing control of the brushless motor, he’s able to directly control the spindle speed via software. This means that spindle speeds can be changed with G-code, allowing for optimized feeds and speeds for different operations. The belt-drive increases torque while separating the motor from the spindle, which should keep things cool, and reduce rotating mass on the spindle itself. Now all [reboots] needs to do is add a DIY tool changer!

Much More Than a Desktop Mill: The DIY VMC Build

A VMC (vertical machining center) is essentially a CNC vertical milling machine on steroids. Many CNC mills are just manual milling machines that have been converted to CNC control. They work nicely, but have a number of drawbacks when it comes to real world CNC milling: manual tool changes, lack of chip collection, lack of coolant containment, and backlash issues (which a manual machinist normally compensates for).

These problems are solved with a VMC, which will usually have an automatic tool changer, and an enclosure to contain coolant and wash chips down into a collection pan. They are, however, very expensive, very big, and very heavy. Building one from scratch is a massive undertaking, but one which [Chris DePrisco] was brave enough to take on.

Continue reading “Much More Than a Desktop Mill: The DIY VMC Build”

Hackaday Prize Entry: A CNC Plasma Table

CNC routers and 3D printers are cool, but the last time I checked, cars and heavy machinery aren’t made out of wood and plastic. If you want a machine that will build other machines, you want a CNC plasma cutter. That’s [willbaden]’s entry for the Hackaday prize. It’s big, massive, and it’s already cutting.

A plasma CNC machine isn’t that much different from a simple CNC router. [will]’s table controller is just a GRBL shield attached to an Arduino, the bearings were stolen from many copy machines, and your motors and drivers are fairly standard, barring the fact they’re excessively huge for a simple 3D printer.

The real trick up [will]’s sleeve is the controller interface. For this, he’s mounted a Raspberry Pi display, a big, shiny, red button, and all the associated electronics behind a beautifully rusty welded enclosure. This part of the build just sends gcode over to the GRBL shield, and is doing so reliably. Right now [will] is looking for some way to save, arrange, and queue jobs on the Pi, a problem that is almost – but not quite – the same job Octoprint does. A software for big, mean CNCs that spew exotic states of matter is an interesting project, and we can’t wait to see where [will] goes with this one.