Smoothieboard, The Be-all, End-all CNC Controller

September 30, 2013 by Brian Benchoff 74 Comments

A while back we took a look at electronics boards for 3D printers, going over the cost and benefits of the most common electronics boards for printers, laser cutters, and mills. One of the most impressive boards was the Smoothieboard, but finding a supplier back then was a little difficult. Now, the Smoothieboard is up on Kickstarter, giving everyone the opportunity to get their hands on this very cool CNC control board.

While most RepRap and 3D printer controller boards use an ATMega or other 8-bit microcontroller, the Smoothie uses a 32-bit ARM chip in the form of an NXP LPC Cortex-M3 chip. Not only does this allow the Smoothie to do some very cool things with your machine – native arcs and circles, for example, but this better hardware also allows for Ethernet, drag-and-drop firmware, and exposing the USB port as both a serial port or mass storage device.

The Smoothie comes in three flavors, with either 3, 4, or 5 stepper motor drivers. These Allegro A4982 drivers are good enough for any 3D printer, laser cutter, or small mill, but the broken out pins allow for stepper drivers supplying more than 2A of current.

Everything on the Smoothieboard is modular, meaning this board is equally capable of powering a RepRap, mill, laser cutter, or plotter. There’s even a planned control panel called the Smoothiepanel, making this a great choice for your next CNC build.

Turn A Decommissioned Robot Into A CNC Machine

September 26, 2013 by Adam Fabio 42 Comments

adeptRobot

Some of us may have been accused of living in Mom’s basement – [Benjamin] kicks it up a notch by keeping an industrial robot in his parent’s ~~attic~~ shed loft.
[Benjamin] was tasked with stripping down some retired equipment at work. It turns out the “retired equipment” was three Cartesian robots from Adept Robotics. These are large industrial XYZ platforms capable of high speed movements (3000 IPM rapids!).

Getting from a decommissioned machine to a working CNC is never a simple path. In this case [Ben] was able to make the transition relatively easily. Each axis of the robot has a 400 Watt Yaskawa servo with a 65k encoder and brake. The original Adept servo amps and control system was still working, so he kept it. The controllers were new enough that they communicate over a daisy chained IEEE1394 (Firewire) link. That is relatively modern compared to some of the conversions we’ve seen in the past. The final piece of the puzzle was ~~G-code creation~~ Translating common G-code to a format his machine could recognize. Ben chose MeshCAM for the task.

One problem [Ben] ran into was stuttering on the X-axis. The original machines only had a single sided drive system on the X-axis. Single side is fine for an assembly machine that doesn’t see any tool load. However for a CNC machine that will see spindle loads, a single side drive creates a twisting force which threatens to rack the entire frame. He used one of the drive systems from his spare robot to convert his main machine to a double-sided drive, eliminating the issue.

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LIB3 Plans To Bring Contract Manufacturing To The Masses

September 24, 2013 by Adam Fabio 20 Comments

LIB3's paste system — LIB3’s paste system

LIB3 is an open source hardware start-up from upstate New York. Thus far, the team has made some interesting products such as the piLED kit. However, they have big dreams for the future. LIB3 plans to become a contract assembly house specifically targeting low volume makers. To do this they have to build their own tools. LIB3’s latest project is a solder paste dispenser for surface mount components. Traditionally solder paste is applied with stencils made of stainless steel. In more recent years laser cut kapton has become a favorite for low volume production.

Both of these systems require a stencil to be made up. LIB3 took a different approach, and modified an old CNC glue dispenser for paste. The team got their hands on an 1991 vintage X/Y glue dispensing system. X/Y systems in this era were big, heavy affairs with powerful motors. LIB3 removed all the control electronics and built their own system from scratch. New features include direct computer control, and a vision system.

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PocketNC P5 Takes Desktop CNC To The 5th Dimension

September 23, 2013 by Adam Fabio 68 Comments

What do you get when you put together a husband/wife team of a machinist and mechanical engineer? If you’re [Matt and Michelle Hertel], you get a 5 axis CNC, which we think was one of the hidden gems at Maker Faire NY.

Hobby CNC machines have grown by leaps and bounds over the last few years. Nearly all these machines have been 3 axis (X,Y,Z). 5 (and more) axis machines have been around for years in the industrial world. These higher level machines never have made the jump to the hobby/home shop world.

The P5’s two extra axis allow for extremely complex parts to be created in one setup. A good example of this would be a turbine wheel. Compound curves on (and behind) each blade would make this an impossible job for a 3 axis CNC. The P5 was machining these parts all weekend at Maker Faire NY. Even more impressive is the fact that it was cutting Delrin, not wax.

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Learn Machining From An Old School Metal Master

September 20, 2013 by Adam Fabio 24 Comments

In the depths of YouTube there are still some jewels to be found. [Keith Fenner] is one of them. [Keith] owns Turn Wright Machine Works in Cape Cod, MA. From his small shop, He works on everything from sailboats to heavy equipment.

[Keith] describes himself as “An artist, and a jobber, 36 years in the trade”. We think he could add teacher to that list, as we’ve learned quite a bit about machining from his Youtube channel.

One of the interesting things about [Keith] is his delivery on camera. He makes the viewer feel like an apprentice machinist working alongside him. Rather than carefully setup shots with graphics, [Keith] narrates as he works paying jobs. He also has no problem showing us his mistakes – and recovery from them, as well as his victories.

The main tools at Turn Wright are the lathe and mill, but [Keith] isn’t old fashioned by any means. He has a complete PlasmaCAM setup and isn’t afraid to do a little computer work.

Most of [Keith’s] projects are broken up into several videos. One of our favorites is “So you broke it off in your hole”. In this series [Keith] shows what it takes to get a broken screw extractor (or EZ Out) out of a large diesel turbo. Get a feeling for what [Keith] has to offer with his “Day in the LIfe” video after the break.

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BeagleBone Black Does CNC With RAMPS

September 19, 2013 by Adam Fabio 13 Comments

[Bart] Wanted to try controlling a CNC with his BeagleBone black, but didn’t want to invest in a CNC Cape. No problem – he created his own translator board for RAMPS. LinuxCNC for the BeagleBone Black has been available for a few months now, and [Bart] wanted to give it a try. He started experimenting with a single stepper motor and driver. By the time he hooked up step, direction, and motor phases, [Bart] knew he needed a better solution.

Several CNC capes are available for the BeagleBone boards, but [Bart] had a RAMPS board just sitting around, waiting for a new project. Most RepRap fans have heard of the RAMPS – or Reprap Arduino Mega Pololu Shield. In fact, we covered them here just a few days ago as part of our 3D Printering series. RAMPS handle all the I/O needed for 3D printing, which carries over quite nicely to other CNC applications as well. The downside is that they’re specifically designed for the Arduino Mega series. Continue reading “BeagleBone Black Does CNC With RAMPS” →

Stewart Platform Reinvents The Wheel So You Don’t Have To

September 18, 2013 by Adam Fabio 20 Comments

StewartPlatform

[Dan Royer] has noticed that most university projects involving a Stewart platform spend more time building a platform than on the project itself. He hopes to build a standard platform universities can use as the basis for other projects.

Stewart platforms are six degree of freedom platforms often seen hefting flight simulators or telescopes. The layout of the actuators allows movements in X,Y,and Z as well as pitch, roll and yaw. While large platforms often use hydraulic systems to accelerate heavy loads quickly. [Dan] is looking at a smaller scale system. His platform is built of laser cut wood and uses six steppers to control motion.

One of the harder parts in designing a platform such as this is creating a mechanical system that is strong, precise, and smooth. With so many linkages, it’s easy to see how binding joints could bring the entire thing to a grinding halt. [Dan] is currently using RC helicopter ball joints, but he’s on the lookout for something even smoother.

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