Aluminum Cnc Router

http://www.instructables.com/id/Aluminum-cnc-router/

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Aluminum cnc routerby cdroster on March 2, 2014

Table of Contents

Aluminum cnc router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro: Aluminum cnc router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1: Frame Build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 2: Gantry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 3: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 4: Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Intro: Aluminum cnc routerThis Instructable is not going to be a step by step build log of my machine, but an overview of my design and what I learned over the course of this build. Hopefully I canshare a few things to help with your CNC build.

My frame design was based on various moving gantry CNC routers from around the internet, with a few alterations. I chose aluminum as my building material mainlybecause it was easily cuttable with the tools I had available, and I figured it would have much greater stability than a wood frame.

dbc1218's DIY-CNC-router build (http://www.instructables.com/id/DIY-CNC-Router/) guided me through most of the internals of the system such as the linear guide rails,ACME lead screws and nuts, and also with the CNC controller and stepper motors. If you want a step-by-step guide I would strongly recommend dbc1281's instructable.

Step 1: Frame BuildThe frame was built using mostly 1/4in 6061 aluminum from onlinemetals. All of the aluminum cuts were done using a standard miter saw fitted with a carbide blade.Cutting was very precise, and quite fast, even when cutting 1/4x3in plate. A drill press was essential for this project. I learned very quickly that a center punch does nothelp at all with alignment of holes if you choose to drill by hand.

http://www.instructables.com/id/DIY-CNC-Router/http://onlinemetals.com


Step 2: GantryLinear System: 16mm steel shafts and bearing blocks (mainly from eBay).

Acme 1/2in 2-start threaded rods (mcmaster.com). Couplers, anti-backlash nuts, shaft collars (dumpstercnc.com).

bearings (vxb.com).

I went with a 16mm linear system throughout the entire system, 13mm would have probably sufficed, and would have been much cheaper. 1/2in ACME threaded rod mayhave been overkill also. The only problem I have with this gantry is leverage. When pushing on the router bit by hand it easily moves ~1/8in in both the x and y direction. Imay cut the height down a couple inches in the future to combat this problem.

Bosch Colt router mount came from k2cnc.com.

http://mcmaster.comhttp://dumpstercnc.comhttp://vxb.comhttp://k2cnc.3dcartstores.com/Bosch-Colt-Router-Mount_p_11.html


Step 3: ElectronicsController: Gecko 540 and power supply from automationtechnologiesinc.com

Motors: 3x 280oz/in Gecko Stepper Motors

Computer: Old pc with parallel port

Router: Bosch Colt variable speed.

Software: LinuxCNC, Autodesk inventor, Inventor HSM express.

The g540 isn't cheap, but it is reliable and easy to set up. I initially thought about purchasing software to control the CNC, but chose LinuxCNC instead. It comes withtools to setup the g540 in no time at all. I chose the Bosch Colt because it was fairly cheap, and well liked on the internet. Autodesk provides a 2 year license to studentsfree of charge, an extension called HSM express creates gcode files for linuxCNC very easily.

I also purchased an aluminum box from automationtechnologiesinc.com. It is a bit expensive but comes with a lot of nice features in a nice looking box.

Cable Carriers are from ugracnc.com

Step 4: ConclusionFinal build cost was around $1500. The router cuts wood great, and will do aluminum with Cut depth around 1/32in at 15in/min. The build ended up being more expensivethan I was hoping, but it was a good learning experience.

As of now I am using double sided carpet tape to hold pieces to the table, and haven't had any problems with that.

I am not using homing or limit switches. I find it much easier to just home the axises to the edge of my project each time.

http://automationtechnologiesinc.comhttp://www.geckodrive.com/stepper-motors/g723-280-4.htmlhttp://www.automationtechnologiesinc.com/products-page/cnc-controller-box/4-axis-cnc-stepper-motor-driver-controller-aluminum-housing-with-e-stop-switch-power-outlethttp://ugracnc.com/CABLE-MANAGEMENT/Cable-Carrier-18-x-25mm.html


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DIY CNC RouterPlans : How toBuild byMakeItWithJason

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Homemade2'x4' Wood CNCRouter by KylesWoodworking

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Comments

8 comments Add Comment

xr3negadex says: Mar 2, 2014. 4:39 PM REPLYDo you know the name of the site is instructables it is a place where there is step by step instructions on how to build or make something

Lectric Wizard says: Mar 3, 2014. 10:10 AM REPLYThat's rude... While step by step is nice there is plenty of information here to make this a good Instructable !! THANK YOU for sharing !!

superhooper9571 says: Dec 21, 2014. 12:53 PM REPLYA picture is worth a thousand words. Thanks for sharing the pictures. Nice build.

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cdroster says: Mar 2, 2014. 4:42 PM REPLYwhoops

russ_hensel says: Mar 3, 2014. 6:51 AM REPLYIt is nice to give lots of instruction, but combined with the references I think your instructable is a good addition to the site. Thanks.

pfred2 says: Mar 4, 2014. 8:18 AM REPLYI'm just happy to see someone make a CNC router without gobs of 8020 for a change.

supertwang says: Nov 23, 2014. 8:41 AM REPLYHi Pfred2, Funny your comment actually introduced me to 80/20... I'd never heard of it. It seems like a great toolkit, so I'm wondering if your commenthad more to do with how often people use it, or if you thought it was an inferior (capability-wise, not looks-wise) approach. I don't have a lot of toolsaround, so it'd appear to be a pretty sweet solution to building metal infrastructure. Is there some flaw I should know about before buying into thatscheme, or was your comment more about the aesthetics? Curious.

Dave

PS. cdroster, I enjoyed reading about your router build too -- thanks!

pfred2 says: Nov 24, 2014. 9:09 PM REPLY8020 is great if money is no object. Well, as great as extruded aluminum can be I suppose. Although be careful, not all 8020 is first run 8020. If youfind a bargain you've probably found something else too.

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Aluminum Cnc Router

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