For the CNC machining assignment, I wanted to carve a design that represented one of my passions, which is robotics. I found a cute robot design on the noun project and downloaded it into Carbide Create.
Once in Carbide Create, I adjusted the material settings, created all the toolpaths for each contour and pocket I wanted, and adjusted the correct bit to create for a final file ready to cut. I made the paths cut the design first using a 1/16″ bit and then cut the outside with 0.1cm tabs using a 1/8″ bit.
After my file was ready, that is when things began to go downhill. I started up the Nomad3 machine and downloaded my file to the OEDK computer.
I then placed my piece of wood on the machine and switch the bit to the 1/16″ bit. I then zeroed the machine, made sure that the wood block was secured and clicked start!
I then had several failed cuts shown in the photo below. I have numbered each failure and described them following the photo. It was a long night at the OEDK.
1. For failure one, my design began cutting well, but then it slowly reached the edge of the piece of wood and I stopped the machine and canceled the cut.
2. I then adjusted the size and placement of the design and tried to recut the design and it still was too close to the edge of the block. I canceled the cut again and adjusted the dimensions.
3. I then flipped the order of the toolpath cuts so that the outside boundary would cut first. I forgot to switch the bit though and when I went to run it, the bit got caught and I had to stop the cut.
4. For the next failure, I switched to the correct bit and recut. It was STILL running off of the wood block though, so I have to readjust the dimensions.
5. I then drastically decreased the dimensions of the design so that I would not have issues, but of course I still had issues. The print fully cut this time, but the tabs were too small and one broke before the print finished. The design was also off centered from the outside boundary.
Finally, after about three hours, I attempted one last time with changing the tabs to 0.15cm. It finally print correctly! I then printed a second identical piece! I was so excited and proud of my piece especially because it took so much effort and errors to get to.
Post-Processing:
After having the blocks CNCed, I used the bandsaw to cut the excess wood off of my design. I then used the electric sander to sand down all the sides of the block especially the tabs that connected it to the large piece of wood. I also used sandpaper to manually make the edges smoother. I even used small tweezers to pick out the small shreds of wood that fell into the contours of the cut. Finally, I used the air compressor to blow out any extra shreds that were still stuck in the piece.
Once it was fully sanded and clean, I stained the blocks using a walnut finish stain.
After the stain had dried on the blocks, I mixed up a small amount of blue resin and poured it into the eye pockets and the little box in the chest of the robot.
Final Product:
Total Cost Summary:
Wood: $1.50/piece x 7 pieces = $10.50
Machining: Free because of OEDK access
Stain: $10/8oz for 0.5oz = $0.63
Resin: $30/ 144 oz for 15oz = $3.13
Total Cost: $14.25
Clean workspace:
