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Week 01 Project Management

Assignment

  1. Plan and sketch a potential final project
    sketch
    Compact Dremel CNC machine

My goal with this final project is create a compact CNC machine to create designs, parts, etc. While I was writing this I realized that I do not even know how to articulate what a CNC machine actually does.

Claude AI prompt: what is the purpose of the cnc machine and what can i learn from the build? Claude AI answer:

CNC (Computer Numerical Control) machines translate digital designs into physical objects by precisely controlling cutting tools.

What You'll Learn from the Build/Use
Design for Manufacturing

  • Understanding toolpaths, kerf (material removed by the cutter), and how design choices affect fabrication
  • Designing joints and assemblies that account for material thickness and machine tolerances
  • Nesting parts efficiently to minimize waste

CAM Workflow

  • Translating your CAD models into machine instructions (G-code)
  • Setting feeds, speeds, and depths appropriate for different materials
  • Understanding the relationship between tool geometry and achievable features

Physical Intuition

  • How different materials behave under cutting forces
  • Fixturing and workholding strategies
  • Troubleshooting when cuts don't match expectations

Scale and Integration

  • Making parts too large for 3D printing
  • Combining CNC-cut structural pieces with 3D-printed details and electronics

Research & Planning - Final Project

This is a very difficult task. I have several projects that I would like to create as my final project, but I need to be realistic with my skillset and the time I have to dedicate towards this project. Puky, a CLS student that was a Fab Academy student last year, advised us to pick a project that we would use ourselves. That helps.

Process

Step 1: Getting Started

I will probably change my mind (or I have been told I would), but I have come to a decision about my project. I want to fabricate a small CNC machine for the experience so I can build a bigger one and also build projects that utilize the same technology like a pen plotter.

Step 2: Design/Modeling

Currently I am looking at other models to, understand the parts and terminology, determine how they have been constructed and just basically how they work.
1. How to Build a Low-Cost Dremel CNC Machine (1/2) (inspired from Nikodem Bartnik)
2. Can a Dremel CNC actually mill METAL? (Essential Upgrades)
3. DIY dremel CNC Construction

Terminology

Spindle - The motorized rotating assembly that holds and spins the cutting tool; the primary component that removes material from the workpiece.

Controller - The computer or dedicated hardware that interprets G-code and coordinates all machine movements and operations.

Stepper motors / Servo motors - Electric motors that drive precise movement along each axis; steppers move in discrete steps while servos use feedback for continuous positioning.

Lead screws / Ball screws - Threaded shafts that convert rotational motor movement into linear motion along an axis; ball screws use recirculating ball bearings for reduced friction and higher precision.

Linear rails / Guide rails - Precision tracks that constrain and guide movement along each axis, ensuring smooth and accurate travel.

Gantry - The bridge-like structure that spans the work area and carries the spindle; moves along the Y-axis while the spindle carriage moves along the X-axis.

Bed / Table / Spoilboard - The flat work surface where material is secured; spoilboards are sacrificial surfaces that can be resurfaced when damaged.

Collet / Tool holder - The clamping mechanism inside the spindle that grips and secures the cutting tool; collets are sized to specific shank diameters.

End mill / Bit - The actual cutting tool that removes material; comes in various shapes, sizes, and flute configurations for different operations.

Limit switches / Home switches - Sensors at the ends of each axis that establish machine boundaries and the zero reference position.

Emergency stop (E-stop) - A safety switch that immediately cuts power to motors and spindle when activated.

Dust collection port / Dust shoe - An enclosure around the spindle that captures chips and dust, connecting to a vacuum or dust collector.

Work holding (clamps, T-track, vacuum table) - Systems for securing the workpiece to the bed during cutting operations.

VFD (Variable Frequency Drive) - An electronic controller that regulates spindle motor speed by adjusting electrical frequency.

Source: Claude AI
Prompt: List the parts of a CNC machine and what it does in the format of part - definition

Files

File Description
Sketch Final Project

Reflection

What I Learned

After months of trying to figure out what I wanted to create for my final project , I finally decided on a small CNC machine. That is a relief so now I can move forward with my goal.