2017 / MACHINE DESIGN
MULTI-AXIS CNC HOT WIRE FOAM CUTTER 2017 February - June MACHINE DESIGN PERSONAL PROJECT while auditing for FabAcademy 2017 at FabLab Bombay CONTRIBUTORS Jaydip Biniwale (city planner by training), also auditing the course THE CONTEXT / I was working as a ROLE / My contributions can better space designer at the Innovation and be explained by this diagram: Design Centre at Godrej and Boyce Mfg. Co. Ltd. with the Fabrication Futures group. I was involved in improving the existing workshop, and setting up FabLab Bombay. It was then that I took the opportunity of sitting in on the FabAcademy global lectures, in return for helping out participant students with their projects. Conducted by Neil Greshenfeld at the MIT Centre of Bits and Atoms, I found what I believe is my true vocation, through this course. As my final project I worked with Jaydip (JB), to create a multi axis CNC hot wire foam cutter. THE PROJECT / We used open source Gestalt Nodes and Fabnet to create a multi-axis (Y, Z and a rotational axis) hot wire foam cutter, with temperature control, and multiple input interfaces which can be networked via the internet and wifi. It was based on the ‘Machines that Make’ project by Nadya Peek.
COMPUTER AIDED DESIGN PROJECT MANAGEMENT COMPUTER AIDED MANUFACTURING DESIGN INTEGRATION ELECTRONICS PRODUCTION 3D PRINTING SYSTEMS DESIGN
The Finished machine connected to a computer with FTDI
ME
MECHANICAL DESIGN FINAL ASSEMBLY
JB NETWORKING ELECTRONICS DESIGN EMBEDDED PROGRAMMING
Integrated Systems Diagram
INTERFACE PROGRAMMING
SKILLS LEARNED / I acquired a lot of skills outside my architectural background by doing this intensive course along with my full-time consultation job. The ability to learn fast, the ability to integrate things from different fields together into one cohesive solution. Thinking not just like a designer. Troubleshooting, rapid prototyping. Thinking with my hands. I learnt how to solder, design and mill my own integrated circuit boards, learnt about electronic components, mechanical systems, tools and techniques. Every decision was informed by thorough research into individual components or systems. Even though I used to make things before, they were relatively simpler and did not invovle so many different systems. I was highly fascinated by this new world of making more complex things and found myself absorbing like a sponge during this time. 12
+ Tensioning + Structural + Clamping + Computing systems
13
2017 / MACHINE DESIGN
8 mm ID Linear Bearing makes movement along Y-axis smooth
8 mm Stainless Steel Rod forms the rail for movement in Y-axis
26 AWG Nichrome Wire
24x6 mm Compression Springs on both sides, provides flexible tension even when both end effectors move separately
6 mm MDF panels also make the structural frame Range of Y-axis
8 mm Lead Screw provides vertical movement to the end effector body
Cutting Foam Rotary Bed for cutting along rotary A-axis
Flexible Coupling connects stepper motor to the lead screw Stepper Motor 42mm 2.8A, 0.40Nm
Main Power Supply
14
Cylindrical MDF stand for the rotary mechanism made by lasercutting 8 mm Lead Screws provides horizontal movement to the Z-axis body
15
2017 / MACHINE DESIGN
Steps of Assembly
16
The Basic Machine
17
2017 / MACHINE DESIGN
Learning about various components
Preparing for Assembly
Designing a physical user interface and setting up electronics
Different stages during assembly
Testing and troubleshooting components
Various stages of prototypes
18
Testing cutting with the rotary axis
Cutting Experiments using different materials
19