Archive for the ‘Learn CAD’ Category

One day I knew I had a problem.  I just spent 4 hours with my plasma cutter in my right hand.  I had been cutting out patterns I had traced onto a sheet of metal.  These shapes were going to be my new coffee table.  Everyone complained to me that I didn’t have a coffee table.  I thought, “I’ll show them” and began to build one.

Why make a coffee table out of metal you ask?  The quick answer is that I wasn’t much of a woodworker at the time.  On the other hand, I used to weld professionally and knew I could make anything out of metal.  That is how it all began, making a coffee table out of metal.
Now if you knew me, you know that I can’t just make something normal.  My brain is the scheming type that has to do things differently then the norm.  I wanted to make a table that would knock people’s socks off.  I thought a funky looking table, made out of metal, with casters and lights would do the trick.  You know what?  It did. 

I really had a ball making this table.  I mean I had serious fun.  So much so that I started to design others.  I began showing photos of my work to everyone I knew.  On top of that, I was getting good feedback.  I had just found a new hobby, furniture making.  Who would have ever thought I would pick up furniture making as a hobby.

While making this first table a problem arose.  It is the one I mentioned above with my right hand.  After plasma cutting all those parts my wrist really began to hurt.  While welding professionally there was always the threat of Carpal Tunnel Syndrome.  Welders are constantly afflicted by this injury and others because of Repetitive Motion.

If you repeat something over and over and over and over, your body gives out at some point.  After cutting up these table parts, I knew I couldn’t go on doing this for a hobby.  I knew something would have to change or the new hobby would break my body.

That is when I began investigating Hobby CNC.  I call it “Hobby” CNC, because that is how I found it.  There were small groups of enthusiasts on the Internet that were building these machines for the fun of it.  I thought this was the ticket. 

My Initial Thoughts on CNC…
I thought, “If I could build a CNC Plasma Cutting Table?”
I could hook my plasma cutter to it
Create a program of the part I wanted
Cut out multiple parts to my hearts content
Save a lot of time
And Finally…
Save my wrist from the dreaded Carpel Tunnel Syndrome.

I really wasn’t scared of the technology to start with.  I grew up in fabrication shops across the Midwest and had seen these machines in action.  These machine “Operators” were always held in high esteem at the shop.  They always made more Money and always had as much Overtime as they wanted.  I decided if they could do it, I could do it.

CNC hobby projects were not cheap at the time.  I figured I would have to invest $4,000 – $5,000 to build my table (they have come down considerably).  Keep in mind this was in 2000-2001.  For some reason that didn’t scare me off.  I always liked a good challenge and this was it.  With blind faith, I ordered up a CNC Controller and went down to my local steel yard to fill the back of my truck with steel.

Little Did I know…
There was a steep learning curve with CNC.  Building a frame for the machine is only a small part of the project.  Today it is much easier.  The software, components and suppliers are better.  There is an entire cottage industry that has sprung up around CNC to support it.  Some of the best people in the world make their livings servicing CNC Hobbyist needs.

For some reason I figured if I just build this machine it would spit out parts whenever I wanted it to.  Simple, Simple, Simple ran through my head.  Over time, I started to get it.  I didn’t have a teacher, but I started to learn the ins and out of what I was doing.

Other things I had to learn along the way:
CAD Software
Designing Parts
CAM Software
Preparing parts for machining
Simulating Machining
Machining Basics
Cleaning parts

Originally posted 2007-10-30 01:36:30. Republished by Blog Post Promoter

        CNC as a hobby has really seen a huge growth spurt over the last 8 years.  I think I stepped into it about two years after it started cooking in the late 90s.  When I jumped in there were a few CNC Groups going already and about three different CNC Plasma Tables available at the hobby level.  I don’t know where the other machine types were at the time because I came in through the plasma path.  I would guess they were further behind as CNC Plasma Cutters was one of the first areas of CNC to take off in the Hobby arena.

        Most of the growth I would attribute to the Internet.  Groups formed, ideas were shared.  Feedback was given.  People started making “chips” and didn’t look back.  The Internet brought a very expensive technology into garages across the country.  When I built my $4000 CNC Plasma Table a hobbyist class machine was around $10,000 and a commercial machine was $100,000 to as high as you wanted to go.

Originally posted 2007-08-01 23:36:09. Republished by Blog Post Promoter

Introduction to Design
Designing is arguably the most important step to the CNC process.  Why you might ask?  Because it is at the beginning.  This is the planning stage of the process.  If you come up with a bad design, all of your work after this point is lost.  I also think of designing as the planning process.  You need an inventory of what you have to work with before you begin.

Every thing needs some planning to start with.  Whether it is a family vacation or buying a home.  CNC is no different.  You need to think about what you want to accomplish before you ever invest any time or money.  Now I am not saying you need to have a perfect plan.  What I am saying is that you need to at least have a plan.  Believe me I have had many plans and virtually none of them ended up perfect.  What it did do was give me a guide to follow.  A roadmap of sorts.
You also need to know your limitations.  For example, don’t go designing a metal sign if you have a CNC Wood Router and nothing else.  Or, you want to make a 2” thick wood routed sign, but your CNC Wood Router only has 1” clearance.  You will need to know you own personal capabilities and your shop’s capabilities.  Once you know that, you can improve your situation either through training or purchasing other tools.

Where do good design ideas come from?
First, look around.  Take an interest in your environment and all the various objects around you.  Look at how things are built.  Generally, I don’t look at the overall design.  I try to figure out how they build a specific part or area of the design.  For example a unique latching mechanism.
A lot of good design is experience.  Experience comes from failure as many people have said.  The bottom line is you need to try stuff and experiment with ideas.  Pick the ones that are useful and go with them.  Leave the failures on the scrap pile and move on.  Never marry yourself to an idea as being perfect.  Virtually everything can be improved upon.

Know what you want before you build it
When designing it is very important that you know what you want to build.  You don’t need to know every detail, but it helps if you have a general idea.  For example, the item may need to fit inside a certain dimension.  This dimension could be the size of the box used for shipping the item to the customer.  This is a requirement of your design.  Requirements can either be self-imposed or put upon you by someone else.
Another example may be building a piece of art.  You may want to make the piece out of Stainless Steel because it would reflect the sun and hold up in the environment.  Then you find out Stainless Steel is too expensive and that you don’t have the equipment to work with it.  Stainless usually maxes out your equipment. 

You need to have a plan, at least a rough one.  You will need to take inventory of your capabilities and match your design to them.  You will also need to get all requirements for the project before you ever begin.  If you do that, you will not waste extra time redesigning again and again.

What are the limits?
Really, you are the limit.  You brain and its thinking are the limit.  If you can think of it, someone, somewhere can probably build it.  The more you expose your brain to different things and ideas, the more connections it will draw.  This is where your creativity will come from.  You need to feed your brain interesting information and it will spit back some interesting designs.

Part vs. Art
In designing for CNC, there are two different paths.  Art or Part.  By art, I mean a design that may have extra embellishments, curves, features, text, etc.  By part, I mean a square with a hole in it.  Or a triangular gusset.  Art is usually flowing or an image of something.  It could also be a sculpture for example.
When you are designing art, you normally keep a sketchbook with your ideas.  You note them.  They don’t have to be perfect, just roughed out.  Sometimes I cut things out I find interesting and put them in my sketch book.  Things like interesting shapes, interesting images or even a unique way to bolt things together.

When you are designing parts, you are dealing with deadlines and customer requirements.  There are no extra things to personalize or stylize the part.  The part is utilitarian and gets the job done.  This is the majority of what CNC is used for.  This is what various industries use CNC for.

Designing on Paper
Most people scratch out their initial ideas on paper to rough them out.  I like to draw things out in a print, drafting or blueprint format.  This style uses multiple looks and multiple angled drawings to convey what you mean to someone else.  I picked up this style of drawing while working in a manufacturing environment.  Some wood workers will also recognize this style.  Think of a time when you bought “The Plans” to building a birdhouse.

Designing with a Computer
This is what I use next.  Once I have something roughed out, I like to translate it into a computer.  Things are more exact.  You get a feel of the size or how parts fit together.  You also get the benefit of saving your work and coming back to it later.  You can even share your files with others when working on a project.

My Design Computer Setup
A number of people have asked me what my design setup is at home.  Here is what I like to use.  First a powerful computer with plenty of processing power.  Make sure to get as much processing power, RAM and a big hard drive.  Don’t skimp here.  CNC software uses a lot of system resources and you will save time by having a computer that can handle the load. 

Next, buy a dual monitor setup.  You will need a graphics card with a dual output head and two monitors to output to.  Most home users can install this themselves.  Dual monitors keep you focused.  I really like being able to keep my computer screen clean of various design palates that seem to clutter it up.  A dual monitor is perfect for this.

Originally posted 2007-11-10 03:33:28. Republished by Blog Post Promoter

Electronics – There are many electronic components you can build yourself.  Do you like to solder together power supplies, cooling fans, drivers and processors? CNC would appeal to you.

Design – Do you like to think about things in your mind?  Then conceptualize them into a computer.  Do you have a little inventor inside of you trying to get out?  CNC would appeal to you.

Manufacture – Do you like to make things in a process fashion?  Step by step, process by process.  Do you like to optimize and test and make processes more efficient?  CNC would appeal to you.

End Design – Do you have a result or end design in mind?  This is what happened to me.  I knew where I was.  I knew where I wanted to go.  I then used CNC as a bridge to get there.  If you have an end design in mind that is repetitive, then CNC would appeal to you.

Money – Do you like money?  Boy is that a question.  Many hobbyists get into CNC to make some extra money or start their own business.  Yes, you can make parts and sell them.  Guess what, after you design the part, you never have to do that again.  You can just call up the program and make some more.  Months and years later…forever.  CNC appeals to people who want to make money.

Challenge of Building a Machine – Some people just get bored and want a project to work on.  Building a machine that does something appeals to them.  Think of the Model Builders, Woodworkers, Metal Workers and any other type of builder you know.  CNC appeals to the builders of the world.

The Entire CNC process – I fall strongly into this category.  I started into CNC because of a problem, but stayed because I love the whole process of it.  I like to design things.  I like to build things.  I like to make money.  I like the challenge.  I like the whole enchilada.  That is what I want to share with you.

Originally posted 2007-09-06 04:06:00. Republished by Blog Post Promoter

What I used to do…
Before I found design software I was in the stone ages.  I would actually hand lay out a template on a piece of paper.  Then cut it out.  Next, I would tape the design onto a piece of steel and trace around it with a Sharpe Marker.  Finally, I would cut out the piece I wanted.
No matter what, it was never exact.  There would always be something wrong.  Things like wavy lines, gouges and “unique parts” were the norm.  Measurements were never as exact as I would have liked either.  That usually caused some fit-up issues, followed by some grinding.  If you know anything about fabrication, grinding is the enemy of your time.

Why use Design Software?
I knew there had to be a better way so I found some design software to try out.  Yes, it does take some time to learn.  Think about it, like anything else in life, something that is worth it takes some time.  This is also the situation of taking one step backwards to move ten steps forward.

Here are some advantages of using Design Software:
Saved file you can use over and over
Transfer the design to others
Can use exact measurements
Repeatability in design

Here are some disadvantages of using Design Software:
Cost money
Takes time to learn
May not be the quickest way of making something if it is a “One Off”

My Definition of Design Software
If you are an engineer, you will probably consider CAD Software as design software.  That is true.  But what I am talking about here is “Creative” Design Software.  These software packages are used by creative types for print, web design and logo design.  This software is great for creating designs that flow and are artistic in some way.
Design software can be boiled down to what it is good at.  If you want to make a square with a hole in it or a triangular gusset, then CAD type design software works great.  If you want to cut out a Cowboy on a Horse, then “Creative” Design Software is the only way to go.

Here are some examples of work for “Creative” Design Software:
Plasma Art
Router Art
Signs
Engraving

Originally posted 2007-10-30 01:47:46. Republished by Blog Post Promoter

CNC Stomp Pad Video 2 – Illustrator Design

In this next video we go over the design of the CNC Stomp Pad.  We use Adobe Illustrator to sketch it out.  We prepare something that a CNC Plasma Cutter could follow.

Originally posted 2007-11-16 15:58:58. Republished by Blog Post Promoter

In this video, we go over the CAD portion of the CNC Process.

In this CNC Basics Video we go over CAD. CAD Stands for Computer Aided Design. During the CAD step we take our initial design an In this CNC Basics Video we go over CAD. CAD Stands for Computer Aided Design. During the CAD step we take our initial design and translate it into the computer. We do this CNC Step so we can change the design, resize it, save it, transfer it to someone else, etc. Recording our CNC Design into CAD gives us flexibility.
During CAD we learn we first design parts, then assemblies, then groups, then machines. We also learn there are different types of CAD Software. 2D, 2.5D and 3D. These types also come in different software packages from inexpensive to expensive. You can spend up to the sky if you want.
The trick is to match the CAD Software Capabilites with your CNC Needs. You don’t need high power 3D Modeling CAD if you make simple parts day in and day out.
Tomorrow’s lesson is CAM. Computer Aided Manufacturing.

CNC Stomp Pad Video 3 – Rhino 3D

In this CNC Video we take the design into Rhino 3D.  We scale it to the size we want and then convert it into a DXF File.  That prepares it for the next stage which is CAM.

CNC Stomp Pad Video 1 – Project Intro

Here is the first video in the CNC Stomp Pad video Series.  In this video we outline the project and what we are going to be making.  Check it out!