Large Format CNC¶
During this week we learned how to use the CNC Wood Router. Through this machine we were able to make complex designs using wood which were then possible to be assembled into all sorts of things from stools, frames, bookstands, to even swords. Guess what I made!
Wood Router¶
A wood routing machine is a power tool that is used to shape and cut various types of wood. The machine uses a high-speed rotating cutter, called a router bit, which can be configured to cut a variety of shapes and patterns into the wood. Wood routing machines can be used for a wide range of applications, including creating decorative trim, making furniture, and creating precise joinery. They are commonly used in woodworking shops and by hobbyists who want to create unique and intricate designs in their woodworking projects. With the right bit, a wood routing machine can also be used to cut other materials such as plastic, metal, and composites.
CNC (Computer Numerical Control) wood routing machines are automated woodworking machines that are programmed to follow precise cutting paths based on digital designs. These machines use computer-controlled routers to shape and cut wood with a high degree of accuracy and precision, often achieving results that would be difficult or impossible to achieve by hand. CNC wood routing machines can be used to create complex shapes, intricate designs, and repetitive patterns, and they are ideal for mass-producing high-quality wood products with consistent quality. They are commonly used in woodworking shops, furniture factories, and other manufacturing settings where speed, precision, and repeatability are important. CNC wood routing machines are operated using specialized software that allows users to create and modify designs, select cutting tools, and control the cutting process.
Safety x Points¶
When using a CNC wood routing machine, there are several important safety aspects to keep in mind. These machines can be dangerous if not used properly, and it is important to take the necessary precautions to prevent accidents and injuries. Here are some safety steps to start, operate, and stop a CNC wood router:
- Wear protective gear: Before starting the machine, make sure to wear protective gear such as safety glasses, hearing protection, and gloves to prevent injury.
- Inspect the machine: Check the machine for any damage or defects before starting it, and ensure that all safety guards and shields are in place.
- Secure the workpiece: Secure the workpiece firmly to the machine’s bed or table, and make sure it is properly aligned and supported.
- Set up the cutting tools: Choose the appropriate cutting tools for the job, and make sure they are properly installed and tightened.
- Program the machine: Use the CNC software to program the machine to follow the desired cutting path, taking care to avoid any collisions or other potential hazards.
- Start the machine: Turn on the machine and begin the cutting process, staying a safe distance away from the moving parts.
- Monitor the machine: Keep a close eye on the machine while it is in operation, watching for any signs of problems such as unusual sounds or vibrations.
- Stop the machine: When the cutting process is complete, turn off the machine and wait for all moving parts to come to a complete stop before removing the workpiece.
- Clean up the area: Clean up any debris or sawdust in the area around the machine to prevent slips and falls.
It is important to follow these safety steps and to exercise caution when using a CNC wood routing machine to prevent accidents and injuries.
Material x Properties¶
| Type of Wood | Properties | Best Applications | Potential Issues | Finishing Options | Recommended for CNC |
|---|---|---|---|---|---|
| Pine | Soft, lightweight, easy to work with, low cost | Framing, cabinetry, furniture, trim, paneling | Knotty appearance, prone to warping and splitting | Stain, paint, seal | Yes |
| Oak | Hard, heavy, durable, attractive grain patterns | Furniture, flooring, cabinetry, trim | Expensive, can be difficult to work with, susceptible to insect damage | Stain, varnish, oil | Yes |
| Maple | Hard, heavy, fine grain, easy to work with | Furniture, cabinetry, flooring, musical instruments | Expensive, prone to blotching when stained | Stain, paint, seal | Yes |
| Cherry | Hard, durable, fine grain, attractive red-brown color | Furniture, cabinetry, flooring, decorative accents | Expensive, can darken with age and exposure to light | Stain, varnish, oil | Yes |
| Mahogany | Hard, durable, attractive grain patterns, rich reddish-brown color | Furniture, cabinetry, boat building, musical instruments | Expensive, can be difficult to work with, susceptible to insect damage | Stain, varnish, oil | Yes |
| Walnut | Hard, durable, attractive dark brown color, easy to work with | Furniture, cabinetry, decorative accents | Expensive, can be difficult to find, prone to fading and darkening with age | Stain, varnish, oil | Yes |
| MDF | Consistent density, smooth surface, low cost | Cabinetry, furniture, molding, decorative accents | Prone to chipping and swelling when exposed to moisture | Paint, seal | Yes, with appropriate cutting tools and dust collection |
Design x Files¶
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For this week’s project, I decided to make a katana out of wood. This katana was inspired from Demon Slayer, an anime that I am a fan of. Below is a picture of this katana in the show:
Using this as an inspiration I set out to design a similar katan using Solidworks, with this being the final result of that:
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Afterwards, it came down to cutting the pieces of the katana. Using the CNC wood router in the lab (Shopbot 3000), I saved and sent the files as DXF format. Then using the VCarve software, I layed out the DXF files on the board template. Then I chose the appropriate toolpath details for my design, some were pocket toolpaths for the hilt to slide into the blade while some were around while others were inside cuts. Below are a few screenshots demonstrating this:
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Once the design was set, the machine was then controlled to cut the parts. Note: a sacrificial piece of wood is placed on the wood (MDF) I used to ensure that any too deep cuts don’t damage the machine bed. Below is a picture of the machine operating:
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Once the design was cut, the hilts had to sanded down to ensure it has a good finish and that it would fit into the blade. Of course, there were a few failure pieces cut, this is due to tolerance issues alongside some failure from the machine’s side as well as human error.
Then once everything was sanded down for a good surface finish and to fit, the assembly process began which involved the use of a binder which acted as a press fit joint. This piece of wood was inserted to hold the blade alongside both pieces of the hilt. A hammer was used to push the binder pieces into place. Below is a picture of a previous version of the katana along with an unfinished version of the current katana: