Sorry I've been around the forums for a while, but I've been working on a home-built CNC router. Expensive? To be honest, it can be as cheap as you like. Obviously the cheaper it is, the less accurate and slow it will be, but I reckon it can be done for £200 if you are desperate. Anyway, the idea is a three-axis CNC Router machine, controlled by the computer to re-produce your CAD drawings in materials such as wood and aluminum.
Here's what I got so far:
The "gantry" (large part astride the two long rails) moves along the steel rails on bearings, as does the cross slide which moves across the gantry to give you the x and y axis on your drawings, the z-axis will hold the router and slides nicely on bearings in between stainless steel tubing. The three-axis each have a single nut attached to them, and this will be driven by a length of threaded rod, connected to "stepper" motors, which turn the rod, hence moving the axis. Stepper motors are so called because they can be turned a fraction by the computer controlling them, allowing accurate positioning of the axis. Hmmm, think I'm explaining too much!!
I have several detailed pictures if anyone is interested, and will update as and when, but just thought I'd test the water first! It's not exactly molding, but hopefully it should stir a few brains! Let me know what you think!
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