Roctech CNC Router

Tuesday, April 25, 2017

From Theoretical Design to Practical Manufacture on Laser Cutting / Etching Machines

A laser cutters / etching machine will cut, etch and shape a range of materials with great precision. The process is started with the designer using a vector or bitmap drawing package such as Corel Draw or Corel Paint. A design is produced and saved in the normal way.

When the drawing is ready to be etched or cut and shaped on a laser machine, the file menu is selected and from this the print menu and sent to the laser cutter in the same way as sent to a printer.

The computer is normally connected to the laser cutter via a USB connector. The file is transferred from the computer to the laser cutter. The laser cutter converts the design into coordinates and it is these that are used to move the laser lens system to the correct positions when cutting takes place.

Monday, April 24, 2017

Introduction to Laser Cutting / Etching Machine -Part 2

Although seemingly high end, classy and high grade, laser cutting / etching machines are quite simple in the way they work. The lens system that controls the position of the laser is itself moved by a motorised slide control system. This allows movement in any direction. The control system moves according to the programme being used by the machine. The diagram shows the LID open - however, the laser will not operate unless the lid is closed. This is a safety feature.

The work/material being engraved or cut by the laser is held firmly in position on a vacuum bed. The work/material is normally positioned in the top left corner as shown on the diagram below. The machine operates with three axis, X, Y and Z. The top left corner is regarded as coordinates (0,0,0), this is sometimes called zero point or the start point.

The diagram below shows a coat of arms being etched on a sheet of transparent glass. The lens unit focuses the laser in exactly the right position as it cuts / etches.

A close up of a typical lens system can be seen below. The lens system slides up and down the motorised slide control system.

The laser is deflected from it source within the machine through a series of precision lenses/mirrors and focussed accurately on the area to be cut/etched. The laser removes small dots of material, up to 1200 dots per inch. This means that it is able to cut extremely accurate shapes and produce astonishingly detailed etchings. The laser cutter is similar to an ink jet printer. The printer sprays ink onto the paper in a series of dots that make up a picture or text. The laser cutter removes material in a series of dots producing pictures / etchings and shapes cut away from the surface of the material.

The microprocessor controlled height guide ensures that the laser cuts to the correct depth.

If a circular or curved product such as a glass container is to be etched then a motorised roller system is used. The rollers are controlled by the microprocessor, rotating the glass at exactly the right speed and direction. This allows etching to be produced accurately on the surface. The height guide ensures that the laser is set to the correctly at all times. This system allows uneven surfaces to be etched as well as surfaces that are uniform.

Introduction to Laser Cutting / Etching Machine -Part 1

Although the first industrial machine was introduced in 1988 by a USA based company called EPILOG, laser cutting and etching machines are relatively new in schools and colleges. Laser cutters/etching machines are capable of very accurate work as a laser is used to etch or cut material precisely. They can be used in the cutting/ shaping of precise parts for prototype architectural models and etching a range of materials such as glass, marble, woods, plastic and even stainless steel.

A framed engraving of a family coat of arms is shown below. Inside the wood frame is a small sheet of glass and the coat of arms has been engraved/etched into the top surface using a EPILOG laser cutter / engraver. Before the introduction of laser cutters this process would have taken a considerable amount of time and the coat of arms would have been engraved by a skilled craftsperson, using a range of sophisticated glass engraving tools.

The laser cutter / engraver uses a laser ‘beam’ to etch the shapes to precisely the correct depth. The laser machine takes a fraction of the time to manufacture a piece of work of this type compared to traditional methods.

LASER CUTTING STEEL PLATE

More examples of objects engraved / cut using a laser cutter/etching machine are shown below.

A typical Laser Cutter / Etching Machine is shown below. The example shown is no larger than a typical photocopier. A vacuum bed holds the work to cut/ engraved securely and the lens system directs the laser as it cuts / etches the material.

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The way to Export STL Files From CAD Software

When manufacturing a product / a model using a 3D printer, the first stage is to design and draw it in CAD software.

Once completed, the design will be exported as an STL file ( or OBJ / DAE / AMF formats), which is likely to be compatible with the software provided by the 3D manufacturer. Some 3D manufacturers use open source software such as ‘CURA’.

Open up the manufacturers recommended software and import the STL file.

The design can then manipulated, such as rotated and scaled. It is then ready for saving as a model.

The model (file) can then be copied to an SD card, which in turn is inserted into the 3D printer SD-card slot, ready for use.

Introduction of Using 3D Printers for Filament Spool

3D printing is already a process, whereby 3D CAD designs are manufactured on machines capable of producing a solid form / model.

3D printing has already been as important as an industrial process, especially in the production of some tools, textiles, toys, jewellery and a range of components. The technology also has been used in the medical world, in the manufacture of custom made prosthetic limbs and hearing aids. It even has a practical application in the world of dentistry. Research has been taking place for several years on ‘bioprinters’. These are complex 3D printers, capable of printing bio-structures, used in surgery.

The cost of 3D printing machines is falling and it is now possible for most hobbyists and educational establishments interested in this area, to purchase cheap and reliable machines. An example of a typical 3D printer is seen below.

3D printers construct a ‘model’ by building up layer upon layer of PLA, Nylon or ABS, fed from spool, usually at the back of the printer. Each layer is a fraction of a millimetre and building even a small model can take some time. The PLA / ABS is purchased in the form of filaments on open spools (see opposite). Filaments tend to be 2.85mm diameter (known as 3mm filament), rolled on to a spool. The spool fits on a roller, normally on the back of the 3D printer.

The ABS /PLA is heated as it is drawn through the print head, which moves side to side. As the print head moves, it lays down a layer. This is slowly built up, producing the final 3D object. Different resolutions can be selected, depending on the quality of model required (e.g. 20 micron (Ultra high), 60 micron (High), 100 micron (Medium), 200 micron (Low))

Sunday, April 9, 2017

List of More Advantages OF A 3D Modelling and Questions

Advantages:

1. Complete 3D models can be manufactured, including those models with hollow parts which could not possibly be made by hand in one piece, even by the most sophisticated engineers or craftsperson. Parts such as bearings, engineering parts and complex working models can also be manufactured.
2. A variety of resins and waxes can be applied to the completed model. These increase the strength of the model, its temperature resistance and also allows paint and finishes to be applied realistically.
3. A two part urethane can be added to the model to give it the properties of rubber.
4. Models can be electroplated so as to give the look, feel and gloss of a range of metals.
5. Prototyping machines such as the ZPrinter 310 can even be utilized to produce highly accurate patterns for casting.
6. Manufactured model parts can be combined with real parts to produce a fully functioning product that can then be tested and evaluated

QUESTIONS:
1. What are the advantages of making an accurate model of a prototype using a 3D printer?
2. Draw a simplified sequence drawing of the stages involved in making a prototype using a machine such as the Z310 3D printer (from Z-Corporation). Add notes to help explain each stage.
3. What is the meaning of the term C.A.D. ?
4. How does making a 3D model of a product help a design team develop the product?
5. Research 3D modelling machines using the internet. Collect information such as the cost of machines, where they are made and what they are capable of producing. Include pictures/photographs.
6. Do you think that sometimes there is no need to use an expensive piece of equipment such as a 3D printer to make a model? Explain your answer.

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How to Manufacture a Model Using the 3D Printer

The model which is to be manufactured is to build up one layer at a time. A layer of powder will be automatically deposited into the model tray. The printer head will then apply resin in the shape of the model. The layer dries solid almost immediately. The model tray then moves down the distance of a layer and another layer of power will be deposited in position, in the model tray. The printer head again applies resin in the shape of the model, binding it to the first layer. This sequence occurs one layer at a time until the model is fully completed.