066 FOAMCORE CNC: VISUAL TOOL GLOSSARY 3/17/2011 ILAN E. MOYER SHEET 1/15 PLIERS A needle-nose or any other variety will work well. WORK SURFACE Find a sturdy table that is in a well-lit area. Ideally you’ll be working with 40” x 30” sheets, so a suitably sized surface will help. CUTTING MAT A large piece of cardboard will do, but I would highly recom- mend a cutting mat. Mine is 18”x24” and made by Artool. MARKING TOOLS I use an ultra fine point black Sharpie, but if you’d prefer, a pencil and eraser will work as well. CIRCLE STENCIL The two hole diameters which you’ll need to mark are 5/8” and 1-1/8”. A compass will work just as well. COMPASS A substitute for the circle stencil. > 16” RULER Highly recommended. A 24” C-Thru ruler will make your life much easier. Make sure that it has 1/16” markings throughout. RIGHT TRIANGLE These instructions are designed to take advantage of the factory-square edges of the foamcore. This tool is optional. RAZOR KNIFE I highly recommend getting an Olfa knife. It is difficult to cut 1/2” foamcore with just an Exacto. WIRE CUTTERS These will be important for cutting thin steel cable and stripping the stepper motor wires. SMALL WOOD SAW If you want to save money and use wooden dowels, you’ll need this to cut them to length. A real saw works even better. 12” METAL RULER* I cut everything freehand, but if you’re bad at cutting straight lines or want to better protect your fingers, grab one of these. HOT GLUE GUN Mine is made by Surebonder and has both a high and low temperature setting. I run it at high. SCREWDRIVER You’ll need a medium sized flat head screwdriver.
Transcript
066 FOAMCORE CNC: VISUAL TOOL GLOSSARY 3/17/2011ILAN E. MOYER
SHEET 1/15
PLIERSA needle-nose or any other variety will work well.
WORK SURFACEFind a sturdy table that is in a well-lit area. Ideally you’ll be working with 40” x 30” sheets, so a suitably sized surface will help.
CUTTING MATA large piece of cardboard will do, but I would highly recom-mend a cutting mat. Mine is 18”x24” and made by Artool.
MARKING TOOLSI use an ultra �ne point black Sharpie, but if you’d prefer, a pencil and eraser will work as well.
CIRCLE STENCILThe two hole diameters which you’ll need to mark are 5/8” and 1-1/8”. A compass will work just as well.
COMPASSA substitute for the circle stencil.
> 16” RULERHighly recommended. A 24” C-Thru ruler will make your life much easier. Make sure that it has 1/16” markings throughout.
RIGHT TRIANGLEThese instructions are designed to take advantage of the factory-square edges of the foamcore. This tool is optional.
RAZOR KNIFEI highly recommend getting an Olfa knife. It is di�cult to cut 1/2” foamcore with just an Exacto.
WIRE CUTTERSThese will be important for cutting thin steel cable and stripping the stepper motor wires.
SMALL WOOD SAWIf you want to save money and use wooden dowels, you’ll need this to cut them to length. A real saw works even better.
12” METAL RULER*I cut everything freehand, but if you’re bad at cutting straight lines or want to better protect your �ngers, grab one of these.
HOT GLUE GUNMine is made by Surebonder and has both a high and low temperature setting. I run it at high.
SCREWDRIVERYou’ll need a medium sized �at head screwdriver.
066 FOAMCORE CNC: VISUAL BILL OF MATERIALS (BOM) 3/17/2011ILAN E. MOYER
SHEET 2/15
NYLON BUSHINGSMolded plastic sleeves which are designed to slide on precision shafts. They provide a low-friction bearing for the moving parts of the machine. 1/2” inner diameter.
CONSTANT-FORCE SPRINGThis tape-measure-like spring unravels with consistent force, making it ideal to counter the weight of the Z -axis table and to reduce the load on the Z-axis stepper motor.
DELRIN STRIPThin strips of delrin, an engineering-grade plastic, are used to to reinforce the foamcore in places where it might dent or wear.
QTY: 20 FT $0.39 /FT, $7.80 TOTALMcMaster-Carr P/N 2638T11
WOODEN DOWELSIf you have the ability to cut them, wooden dowels are a cheap and e�ective alternative to steel dowel pins. Purchase at least 18” of both 1/4” and 1/2” diameter wooden dowel.
~$3.00 TOTALLocal Art Supply Store
STUBBY STEEL DOWEL PINS*These pins will get the job done, but are expensive so search for alternatives �rst. If you can’t use wooden dowels, you’ll need to �nd or create cylinders which are 1/2” dia. and 1” long.
SLENDER STEEL DOWEL PINS*These pins will get the job done, but are expensive so search for alternatives �rst. If you can’t use wooden dowels, you’ll need to �nd or create cylinders which are 1/4” dia. and 2” long.
STEPPER MOTORSThese easily controlled motors will move the toolhead around with some degree of precision. The type depends on your controller, but I will be using unipolar motors with a step angle of 0.9°.
WIRE ROPEThe motion system of the machine relies on what is called the “capstan e�ect.” This �ne braided steel cable will prevent the aluminum shafts from spinning without also rolling.
QTY: 25 FT $0.41/FT , $10.25 TOTALMcMaster-Carr P/N 8930T22
DOUBLE-STICK TAPEAn adhesive-paper-adhesive sandwich. Double-stick tape is used to laminate the delrin strips to the foamcore, as well as generally to stick things together.
QTY: 1 ROLL $7.93 /ROLL, $7.93 TOTALMcMaster-Carr P/N 76405A13
ELECTRICAL TAPE*Any color will do. This �exible and somwhat stretchy tape will be used to couple the motors to the aluminum shafts, as well as to insulate wiring connections.
Local Hardware Store
POLYESTER TAPEI really like this plastic-backed adhesive tape, but you could get by with masking tape or clear tape. It is used as a general tape wherever necessary.
QTY: 1 ROLL $6.81 /ROLL, $6.81 TOTALMcMaster-Carr P/N 7630A42
FOAMCORE!You’ll need a 40” x 30” sheet of 1/2” thick foamcore, and a 30” x 20” sheet of 1/4” thick foamcore. Several smaller sheets can be used instead of a big sheet - check the cut patterns.
~$13.00Local Art Store
ALUMINUM SPACERThese spacers coincidentally have the rightinner and outer diameters to adapt the 5mmmotor shaft to the 1/2” aluminum shafts.
SUPERGLUE*Any super glue will do, although the thinner the better. I use this awesome 5cP glue, but 100cP would be OK too. (cP is a measure of �uid viscocity.)
Local Hardware Store
* These are either household items or alternative parts and are not included in the calculated parts price.
TOTAL MATERIAL COST: $119.74
ALUMINUM SHAFTSThese shafts are made to be very straight with highly accurate diameters. They are responsible for both moving and guiding the toolhead andthe Z axis table. 1/2” diameter x 15” long.
066 FOAMCORE CNC: TOP PLATE AND TABLE CUT PATTERNILAN E. MOYER 3/12/2011
SHEET 3/15
SKETCH LINECUT LINE
NOTE: SAVE THIS INTERIOR PIECE BECAUSE IT BECOMES THE MACHINE’S WORK TABLE.
0”
1 1/2”
2 1/4”
12 1/4”
13”
14 1/2”
0”
1 1/2”
2 1/4”
12 1/4”
13”
14 1/2”
MATERIAL: 1/2” FOAMCORE
066 FOAMCORE CNC: BACK PLATE CUT PATTERNILAN E. MOYER 3/12/2011
SHEET 4/15
SKETCH LINECUT LINE
13 1/2”
11 3/4”
1 3/4”
0”
1”3/4”
3/16”
1 1/8”
12 1/2”
0”3/8”5/8” 1”
3 1/2”
4 1/2” 6”
6 3/4”
7 3/4”
8 1/2”
10”
11”
13 1/2”13 7/8”14 1/8”14 1/2”7”
7 1/2”
MATERIAL: 1/2” FOAMCORE
066 FOAMCORE CNC: BOTTOM PLATE CUT PATTERNILAN E. MOYER 3/12/2011
SHEET 5/15
SKETCH LINECUT LINE
0”
1 1/2”
13”
14 1/2”
0”
1 1/2”
13”
14 1/2”
MATERIAL: 1/2” FOAMCORE
066 FOAMCORE CNC: LEGS CUT PATTERNILAN E. MOYER 3/12/2011
SHEET 6/15
SKETCH LINECUT LINE
1 11/16”
0”3/8”5/8”
0”3/8”5/8”
1 1/2”
0”
13 1/2”
0”3/16”
3/16”
13 1/2”
NARROW LEG
WIDE LEG
0”
1 1/2”
7 11/16”
3”
9 3/8”TILING PATTERN
4 1/2”
6”
QTY 2
QTY 4
MATERIAL: 3/16” FOAMCORE
066 FOAMCORE CNC: DELRIN STRIPS CUT PATTERNILAN E. MOYER 3/18/2011
SHEET 7/15
SCORE LINECUT LINE
11 1/2”11”
10”
10 3/4”
0”0”
0”
0”
0”
0”
1/2”
1/2”
1/2”1”
1”
1”
1”
1”
1”
1/2”
1/2”
1”
TOP PLATE LARGE STRIPS
TOP PLATE SMALL STRIPS
BACK PLATE STRIPS
SPLITQTY 2
FULLQTY 2
FULLQTY 2
SPLITQTY 2
SPLITQTY 2
FULLQTY 8
TOP PLATEEDGE STRIPSQTY 4
0”
1 1/2” 3”
BACK PLATEEDGE STRIPSQTY 6
OVERALL LENGTH: 198.5”
TOTAL SPLIT LENGTH: 73.5”TOTAL FULL LENGTH: 125”
Total split length is the total length of1” wide delrin strip which needs to behalved along its length. Total full lengthis the total length of delrin strip which willretain its original width of 1”.
066 FOAMCORE CNC: TOP PLATE DELRIN STRIP PLACEMENT - OUTSIDE SURFACEILAN E. MOYER 3/19/2011
SHEET 8/15
FRONT OF MACHINE
BACK OF MACHINE
TOP
PLAT
E LA
RGE
STRI
P - F
ULL
TOP
PLAT
E SM
ALL
STR
IP -
SPLI
T
TOP PLATE LARGE STRIP - SPLIT
TOP PLATEEDGE STRIP
TOP PLATEEDGE STRIP
TOP PLATEEDGE STRIP
TOP PLATEEDGE STRIP
TOP PLATE LARGE STRIP - SPLIT
NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16”.
066 FOAMCORE CNC: TOP PLATE DELRIN STRIP PLACEMENT - INSIDE SURFACEILAN E. MOYER 3/19/2011
SHEET 9/15
NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16”.
1/2”
3/16”
3/16” 3/16”
FRONT OF MACHINE
BACK OF MACHINE
TOP
PLAT
E SM
ALL
STR
IP -
SPLI
T
TOP
PLAT
E SM
ALL
STR
IP -
SPLI
T
TOP PLATE SMALL STRIP - FULL
TOP PLATE SMALL STRIP - FULL
TOP PLATEEDGE STRIP
TOP PLATEEDGE STRIP
TOP PLATEEDGE STRIP
TOP PLATEEDGE STRIP
066 FOAMCORE CNC: BACK PLATE DELRIN STRIP PLACEMENT - INSIDE SURFACEILAN E. MOYER 3/19/2011
SHEET 10/15
BACK
PLA
TE S
TRIP
- FU
LL
BACK
PLA
TE S
TRIP
- FU
LL
BACK
PLA
TE S
TRIP
- SP
LIT
BACK
PLA
TE S
TRIP
- SP
LIT
BACK PLATEEDGE STRIP
BACK PLATEEDGE STRIP
BACK PLATEEDGE STRIP
BACK PLATEEDGE STRIP
BACK PLATEEDGE STRIP
BACK PLATEEDGE STRIP
NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16”.
TOP OF MACHINE
BOTTOM OF MACHINE
066 FOAMCORE CNC: BACK PLATE DELRIN STRIP PLACEMENT - OUTSIDE SURFACEILAN E. MOYER 3/19/2011
SHEET 11/15
TOP OF MACHINE
BOTTOM OF MACHINE
BACK
PLA
TE S
TRIP
- FU
LL
BACK
PLA
TE S
TRIP
- FU
LL
BACK
PLA
TE S
TRIP
- FU
LL
BACK
PLA
TE S
TRIP
- FU
LL
BACK
PLA
TE S
TRIP
- FU
LL
BACK
PLA
TE S
TRIP
- FU
LL
BACK PLATEEDGE STRIP
BACK PLATEEDGE STRIP
BACK PLATEEDGE STRIP
BACK PLATEEDGE STRIP
BACK PLATEEDGE STRIP
BACK PLATEEDGE STRIP
066 FOAMCORE CNC: STRUCTURAL ASSEMBLY GUIDEILAN E. MOYER 3/19/2011
SHEET 12/15
1/2” 1/2”
NARROWLEG
NARROWLEG
BACK PLATE
WIDELEG
WIDELEG
NARROWLEG
NARROWLEG
TOP VIEW
FRONT OF MACHINE
BACK OF MACHINE
FRONT OF MACHINE
BACK OF MACHINE
NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16”.
066 FOAMCORE CNC: TABLE STRUT CUT PATTERNILAN E. MOYER 3/12/2011
SHEET 13/15
SKETCH LINECUT LINE
5”
4”
3”
2”
1/2”
0”1/4”
0”
3/4”
2 1/4” 3”
13”2”
5/8”
QTY 2
MATERIAL: 3/16” FOAMCORE
066 FOAMCORE CNC: Counter Spring and Table Miscellaneous PiecesILAN E. MOYER 3/20/2011
SHEET 14/15
CUT LINE
MADE FROM DELRIN STRIP MADE FROM 3/16” FOAMCORE
1/2”
1/2”
1/2”
3”
1”
2”
11/4”
11/4”
3/16”
3/16”
LAM
INAT
ED W
ITH
AD
HES
IVE
UN
LAM
INAT
ED
QTY 2
QTY 4
QTY 2
QTY 1
QTY 3
066 FOAMCORE CNC: STEPPER MOTOR MOUNTSILAN E. MOYER 3/20/2011
SHEET 15/15
CUT LINE
SKETCH LINE
1 1/8”
NO
TE: I
F PO
SSIB
LE U
SE A
FAC
TORY
-CU
T ED
GE
OF
THE
FOA
MCO
RE S
HEE
T FO
R TH
IS S
URF
ACE.
0” 0”
1 7/16”
4”
1 11/16”
4”
2 5/16”
1 1/2”0”
3 ” 0”
3/4”
1 7/16”
BACK PLATEMATERIAL: 3/16” FOAMCOREQTY 3
SIDE PLATEMATERIAL: 1/2” FOAMCOREQTY 6
1/2”
3/4”
BEARING STRIPSMATERIAL: DELRIN STRIP, LAMINATED WITH ADHESIVEQTY 12
