This week, we learned how to use the CNC machine. The most exciting part is that the OEDK got a new CNC machine, and we were the first ones to use it. Follow my journey below, and you can create your own Mt.Everest and potentially even climb it.

Step 1: Aim high

For this project, I decided to CNC a provided 3D printed file of Mt.Everest. I opened this file in Vcarve, measured the block of wood I would be using, and inputted that in. I also changed the dimensions of the STL file to match the dimensions of the wood. The initial piece of wood I picked was about 1.4″ thick, and I made the mistake of setting the material clearance to only 0.2″, which meant the total print would take 3+ hours. I created 3 toolpaths: a roughing toolpath, a clearance toolpath, and a final clearance toolpath. The print was then exported as a g-code file. The simulation tool was also very helpful since I knew exactly what the toolpaths would do.

Step 2: Begin your Action-Peaked Adventure

So, even though I knew it would take 3+ hours to print this, I decided to sit through the whole print. I am not sure why, but I did. The process to set up is pretty simple. Upload the file to the carbide software, initialize the machine, and home the machine using a corner probe. Changing the drill bits between the 1/8″ (recommended) and the homing bit was very frustrating though. Before homing, the piece of wood was stuck onto the bed of the CNC machine using strong (well kind of) double-sided tape. The print is now ready to be started.

Step 3: Don’t get your Slopes Up

With vcarve, each toolpath is dedicated to its own file, so each of the files is run separately. I uploaded the first file and followed the normal process. I should’ve run away when I saw the “1 hour 46 minutes” next to the time tab, but I didn’t.  I let it print, but since it was creating so many shavings and interfering with the tape, the piece of wood kept moving. As a result, I paused the print multiple times to change the tape or put additional tape on the side. This may have messed up the coordinates. Once the first file was done, I uploaded the next two as well. One issue I was facing was homing with the probe. The piece was not flat anymore so it was hard to rest the probe on it to get an accurate setting. As a result, during file 3, all the print did was drill holes. This may have been because the drill bit was supposed to create a path at the top, but since the z-axis was not set correctly, the job was done at the bottom of the wood block and the entry path it took was visible at the top. So basically, my 3+ hour job. Fail.

 

 

 

 

 

 

 

 

Step 4: One More Climb

Alright, so not going to sit through the 3+ hour job again. Something needs to change. I got a thinner piece of wood this time and changed the material clearance to about 0.5 in, which was about the same as the thickness of the wood. This cut down the job to about an hour total, and even though the piece was much thinner now,  I was happy with it. Well, now time to do it all over again. It was much more successful and faster this time around. However, there were two times were the wood moved again resulting in two random holes in the piece. I was pretty unhappy with it.

 

 

 

 

 

 

 

Step 5: From Crags to Riches

I decided that I might as well do it all over again, so I found two new pieces of wood and prayed to the CNC gods that these would be my last. They heard my prayers because this time everything ran smoothly. The joy I felt was unexplainable. Of course, it didn’t last very long, because the second time around, it did not run as smoothly. For some reason, the drill would not drill through the wood. This may be because it was a bad piece of wood, but I ended up finding another piece of wood and trying again. This time around, all went well except the very last clearing toolpath was not aligned, so you can see a tiny little defect.

 

 

 

 

 

 

 

 

 

 

 

Step 6: Talls’ Well that End’s Well 

Time to post-process and make it all pretty. I sanded the whole of Everest, stained it with oil, and then clear-coated it. I love the way it turned out, especially because of the wood I chose and the patterns of the wood are clearly visible. Besides that one little defect, I am pretty happy with it! Many lessons were learned such as do not sit through a 3-hour print especially if it is possible to cut down that time. I will tape the sides of the wood so it is steadier next time especially if I am CNC’ing something as complicated as a landscape. Even though it took much longer, I am glad I decided to use vcarve so I now know how to mess with a 3D file using that software.

Step 7: Can’t bear the bad puns anymore? Calculate the costs and Tall it a day

Materials
20 inches of Wood @ $26.98/8ft = $5.62
Matte Clear Coat = $6.48
Clear Stain: 1 can @ $28.28 
Cost to use TXRX Labs that provides access to CNC machine = $90/month 
Total = $130.38
Labor
6 hours * 7.25 = $43.5
Total = $43.5

Grand Total = $173.88