Introduction

In this post, I detail how I cut out a 2D design from a block of wood using the Shapeoko Pro and Nomad 3 CNC machines. I first selected an object to cut, prepared the file, then cut it on the CNC machines, and finally post-processed my object.

Selecting An Object

Using the provided website, http://thenounproject.com, I found a 2D favicon I wanted to cut out. The design I chose is the character Itachi from the show Naruto’s sharingan (or eye):

Link: https://thenounproject.com/icon/itachi-mangekyou-sharingan-5362365/

Preparing the file

Next, I prepared the file using Carbide Create 8. First, I insert the file in the software. Next, I created three toolpaths- a pocket for the inner circle, pocket for the three fishtail designs, and a contour in a circular shape to cut out the object. I set the dimensions of the wood (3.5” width, 6” length, 0.772” depth) and the corresponding measurements for the toolpaths.

The Shapeoko Pro is only compatible with Carbide Create 6, so I transferred my files. In the older version of the software, tabs have to be manually inserted. I insert three tabs on the outer Contour toolpath, with modified dimensions of 0.3 inches by 0.114 inches. 

Cutting the object

I then proceeded to cut my object with the Shapeoko Pro. First, I clamped my object down, selected the correct bit (#102, ⅛ inch), and changed the bit in the machine. Next, I initialized the machine, then used the alignment tool and the Probe function to set a reference starting point. Finally, I hit start on the machine and monitored it during the cut.

Post Processing

Before my cut, I stained the wood using black satin wood stain. Therefore, it would have a nice, clean design once I cut it out with the CNC machine.

The first cut I made did not cut all the way through. I attempted to remove it from the wood block, but in turn it chipped all over. I used the belt sander to remove the imperfections from the sides and the bottom. 

After cutting my objects, I poured resin with red color inside to get my desired product. The ratio suggested online was 10:1 resin to acrylic paint, and I mixed it as such.

After pouring the resin inside my object, I realized I had more left. Not wanting to waste the material, I further cut two more of my objects, in a slightly smaller size so I could cut two of them on one wood block. I proceeded to repeat the cutting and post-processing techniques to produce two more of my objects.

Finally, I sanded and stained the objects.

Final Product

*Workspaces (CNC machine, outdoor table) were cleaned after each use.

Learning Experiences

• During my first cut, the file I prepared in Carbide Create was of a different orientation than the placement of my wood (vertical versus horizontal). Hence, my first attempt resulted in a failure.
• My first object did not cut all the way through, even though I measured the depth of the wood with a caliper and input the exact dimension in carbide create. I realized that I needed to put an object underneath the wood block and overestimate the depth (from 0.772” to 0.79”) so that my object would cut all the way through.
  • The TAs had an issue where the bit would break due to cutting through the wood block on the Nomad 3. Hence, while on Lab Assistant shift, I helped the class by cutting ¼ inch wood pieces to place under the 1x4x6 wood blocks (that I also cut for the class) to ensure that the stock bottom could be overestimated and the bit would cut all the way through.
• While cutting my second object, the bit would not spin despite the power supply being turned on. It took me several troubleshooting attempts to realize the secondary, circular red power button was not switched on. The TAs had a similar issue with the bit while I was on my Lab Assistant shift, so having this error myself helped me to resolve the issue.

Bill of Materials

• 3x 1”x4”x6” blocks of wood – $1.28 (8ft for $6.81)
• ~4oz Epoxy Resin – $4.50 (8oz for $9)
• ~0.5oz Acrylic Paint – $0.15 (2oz for $0.58)
• CNC machine usage time (free)

Total Cost: $5.93 

Conclusion

Overall, I am very happy with how my product turned out, as well as the expertise I gained using and troubleshooting the CNC machines and post-processing with resin. I am much more comfortable with using the CNC machine and am eager to use it for future projects!