Future Projects and Going Bigger and Better

It has been quite an adventure so far. We have gone from a simple bare-bones desktop CNC machine to machines that can cut, draw, and carve with end mills, lasers, pens, and knife points. We have added all sorts of upgrades to our desktop machines and assembled bigger, purpose-built machines.

For our final chapter, we will go over some ideas for even larger and more complex machines that require some additional expertise, electronics, and specialized software. We will start with a scaled-up CNC machine and move on to some more fascinating ideas, such as the following:

• The ShapeOKO line of CNC machines you can purchase that go beyond the basic desktop hobbyist market
• A brief overview of my upcoming OX build and what I have planned for it
• Another brief overview of hot wire cutters, typically for cutting foam
• A look at automating lathe work
• How a fifth axis takes advantage of additional motors so that a CNC machine...

The ShapeOKO

Long ago, I purchased a kit for the ShapeOKO 1. At the time of this writing, they are on version 5 of this machine. This unit is more a “pro” unit that goes beyond the desktop hobbyist but is still small enough to occupy a suitable spot on your desk (albeit, more space than the 3018). The ShapeOKO 1 used belts for movement, using all-metal components. I outgrew mine almost immediately, and it has sat languishing and waiting for its upgrades. The new versions of the ShapeOKO have features that improve rigidity and accuracy that we have discussed elsewhere in this book, such as rails and ballscrews. I will eventually modify mine to use leadscrews and rails and replace the current contrller with an updated controller, or convert it to a purely laser platform. The ShapeOKO is expensive when compared to our 3018s, and the jump in cost is significant. However, it is a more “serious” machine, and if you are doing more than hobby work, this machine...

The OX

I first encountered the OX CNC machine at my makerspace when one of the makers was offering pre-cut metal kits for it. I jumped on the opportunity after I had a chance to do a little research. The OX is an open source, heavier-duty machine that you can find on the OpenBuilds site at https://openbuilds.com/builds/ox-metal-cnc-router-mill.3681/. The Thingiverse site for this machine is at https://www.thingiverse.com/thing:1660320.

As machines go, this one cries out for ballscrews (or heavier-duty leadscrews) very loudly. It is large, heavy, and meant for serious work, such as milling harder materials. Mine has a half-horsepower table router motor as the spindle from DeWalt, but if you decide to build one of these, you can use whatever takes your fancy. If your 3018 is up for the job, use it to cut the carriage pieces for you, or grab the drawings and either hand-make them or send them out for fabrication. There are some parts that need to be 3D-printed, and the brackets holding...

Hot wire foam cutters

I‘ve always liked building RC model airplanes. Many designs are available for free online, and from those, I’ve always wanted to build bigger models made from XPS foam. We discussed using our 3018 machines to mill blocks of foam, but if all we need to do is cut complex shapes without the mess that comes from the spindle, the way to do this is with a hot wire cutter. This is nothing more than a length of wire between two contacts that has sufficient current flowing through it to warm the wire. The heat from the wire melts the foam as you cut through it and allows you to shape it, with almost no mess at all. I have a hand cutter that operates as a wand, but I’ve always wanted to build something with automation. Here’s what my handheld unit looks like. You can also make a handheld cutter using basic materials and a suitable power supply. Just look for instructions on the internet; there are many articles out there.

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CNC lathe

I’ve always wanted to add a lathe to my shop. I have a mini-lathe that I use for machining light woods and plastics, but nothing that can handle larger, harder materials, and certainly nothing automated.

I recently came across a maker on YouTube called Melkano. While the videos Melkano posts are in French, each system he develops has a site in English and French that you can follow. The designs he has are very easy to understand. I have already built one of his early mini-laser cutters, using some scrap extrusions and a few miscellaneous parts. Melkano also has designs for a CNC machine (very similar to a 3018) and a 3D printer. However, what caught my eye was an automated lathe. Unlike all our other machines, the lathe has the workpiece turning at a high revolutions per minute (RPM) rate, while a sharp edge moves along one side and cuts into it. Just think about how the vertical supports of stair rails might be made.

Here is a video of Melkano’s lathe...

A fifth axis

Machines with five axes are unique in that they are able to carve/cut not just on the upward-facing surface but also on all surfaces, bar the one where the workpiece is held. If you think about the engine block of your car, that likely was CNC-machined this way. There are some great videos out there of this, such as the following:

• This video takes a huge aluminum cylinder and turns it into a miniature V8 engine block. Look at all the coolant it uses, and as it carves and cuts, the machine also switches toolheads for each specific job. On top of this, not only does the machine drill holes but it also taps them – spectacular! Here’s the link to the video: https://www.youtube.com/watch?v=wHstzxuryMk.
• Remember our chapter on the 4th axis? Here’s a video that cuts an engine block with four axes, but unlike our modification, you can’t sacrifice one of the axes for it. Here, you have X, Y, Z, AND Theta (the degree of rotation). No, it&...

Summary

We’ve covered a lot of material in this book and built several machines. We’ve also made use of other machines in our toolchain, including 3D printers, other CNC machines, and external machine shops, to effectively set up and utilize our tools. We learned about machines of varying complexity and explored some of the options available to us, not just for the hobbyist but for those who want to take CNC beyond the desktop.

While we have looked at several ways that you can CNC, we also have touched on some very complex means by which you can machine materials, using different concepts. Underneath all these mechanical approaches, the software and the concepts they use are consistent. All of them use some flavor of G-code that is generated by software that derives the toolpath from the base drawing.

As you explore your CNC aspirations, always consider looking ahead and exploring newer technologies. At a minimum, you should have some way to cut with a spindle and...