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A CAD/CAM/CNC approach to case design/construction

A CAD/CAM/CNC approach to case design/construction

2005-07-26 by derekhawkins

Most of us are probably using CAD software to design our PCBs but if 
you're still scribing patterns for drilling and cutouts directly
to metal during case construction then you should consider creating 
CAD templates, printing and pasting them to the metal instead. Even 
if you don't intend using a CNC setup, these templates make things
more accurate for component placement and allow for efficient 
repeatability in case of screw ups. Also, the same template can be 
used as the basis for a dimensionally accurate "decorative"
finish.

Freeware PCB CAD software abounds and while they may be intentionally 
limited when it comes to actual PCB design, generally, there is no 
limitation when used for something like case design if you choose the 
right one. In other words, provided devices such as pads and "known" 
components are not being used, your design can be any size.

The link below is a set of pictures demonstrating the use of CAD 
software and printed templates to CNC drill and center drill 
(equivalent to center punching but under CNC) a 12" X 6"
sheet of aluminum that becomes the front, back and base of the case. 
Holes over 1/8" were drilled manually after center drilling.
Cutouts were nibbled using templates as bounds. Finally, a decorative 
finish printed on self adhesive film was then used for the front and 
back.

http://www.pbase.com/eldata/caseconc

Re: A CAD/CAM/CNC approach to case design/construction

2005-07-26 by lcdpublishing

Hi Derek,

Great pictorial!  I have two questions...

1) What is this product and where to get it 
       "self adhesive film "

2) I notice this is a servo control being built, can you share some 
details about this?  The reason I ask is that I am about to convert 
a machine over to CNC using servos. I have not yet purchased the 
servo drivers yet, so I am curious.

Chris







-- In Homebrew_PCBs@yahoogroups.com, "derekhawkins" 
<derekhawkins@y...> wrote:
> Most of us are probably using CAD software to design our PCBs but 
if 
> you're still scribing patterns for drilling and cutouts directly
> to metal during case construction then you should consider 
creating 
> CAD templates, printing and pasting them to the metal instead. 
Even 
> if you don't intend using a CNC setup, these templates make things
> more accurate for component placement and allow for efficient 
> repeatability in case of screw ups. Also, the same template can be 
> used as the basis for a dimensionally accurate "decorative"
> finish.
> 
> Freeware PCB CAD software abounds and while they may be 
intentionally 
> limited when it comes to actual PCB design, generally, there is no 
> limitation when used for something like case design if you choose 
the 
> right one. In other words, provided devices such as pads 
and "known" 
> components are not being used, your design can be any size.
> 
> The link below is a set of pictures demonstrating the use of CAD 
> software and printed templates to CNC drill and center drill 
> (equivalent to center punching but under CNC) a 12" X 6"
> sheet of aluminum that becomes the front, back and base of the 
case. 
> Holes over 1/8" were drilled manually after center drilling.
> Cutouts were nibbled using templates as bounds. Finally, a 
decorative 
> finish printed on self adhesive film was then used for the front 
and 
Show quoted textHide quoted text
> back.
> 
> http://www.pbase.com/eldata/caseconc

Re: A CAD/CAM/CNC approach to case design/construction

2005-07-26 by derekhawkins

> 1) What is this product and where to get it
> "self adhesive film "

It's thin 11" X 8.5" sheets of self-adhesive plastic film. You can 
get them for laser printers and copiers or for inkjet printers. Print 
on the sheet like paper, spray a protective coating over it if 
necessary, cut then peel off the backing and apply. Bought mine 
(opaque white for laser) several years ago from a place called Pearl 
Paint but they no longer stock it. A Froogle search indicates a place 
called Mister Art having it in stock. Here is a link for laser ready 
products, they should also sell inkjet ready equivalents;

http://www.misterart.com/store/view.cfm?store=001&group_id=3700

> 2) I notice this is a servo control being built, can you share some 
> details about this?  The reason I ask is that I am about to convert 
> a machine over to CNC using servos. I have not yet purchased the 
> servo drivers yet, so I am curious.

A simple plug-n-play setup using drivers from here;

http://www.cadcamcadcam.com/index.asp?PageAction=VIEWPROD&ProdID=11

Before getting the above I also bought and evaluated one of these 
which just about everyone seems to use and recommend;

http://www.geckodrive.com/item.htbml?order_id=0&item_id=G320




--- In Homebrew_PCBs@yahoogroups.com, "lcdpublishing" 
<lcdpublishing@y...> wrote:
> Hi Derek,
> 
> Great pictorial!  I have two questions...
> 
> 1) What is this product and where to get it 
>        "self adhesive film "
> 
> 2) I notice this is a servo control being built, can you share some 
> details about this?  The reason I ask is that I am about to convert 
> a machine over to CNC using servos. I have not yet purchased the 
> servo drivers yet, so I am curious.
> 
> Chris
> 
> 
> 
> 
> 
> 
> 
> -- In Homebrew_PCBs@yahoogroups.com, "derekhawkins" 
> <derekhawkins@y...> wrote:
> > Most of us are probably using CAD software to design our PCBs but 
> if 
> > you're still scribing patterns for drilling and cutouts directly
> > to metal during case construction then you should consider 
> creating 
> > CAD templates, printing and pasting them to the metal instead. 
> Even 
> > if you don't intend using a CNC setup, these templates make things
> > more accurate for component placement and allow for efficient 
> > repeatability in case of screw ups. Also, the same template can 
be 
> > used as the basis for a dimensionally accurate "decorative"
> > finish.
> > 
> > Freeware PCB CAD software abounds and while they may be 
> intentionally 
> > limited when it comes to actual PCB design, generally, there is 
no 
Show quoted textHide quoted text
> > limitation when used for something like case design if you choose 
> the 
> > right one. In other words, provided devices such as pads 
> and "known" 
> > components are not being used, your design can be any size.
> > 
> > The link below is a set of pictures demonstrating the use of CAD 
> > software and printed templates to CNC drill and center drill 
> > (equivalent to center punching but under CNC) a 12" X 6"
> > sheet of aluminum that becomes the front, back and base of the 
> case. 
> > Holes over 1/8" were drilled manually after center drilling.
> > Cutouts were nibbled using templates as bounds. Finally, a 
> decorative 
> > finish printed on self adhesive film was then used for the front 
> and 
> > back.
> > 
> > http://www.pbase.com/eldata/caseconc

Re: A CAD/CAM/CNC approach to case design/construction

2005-07-26 by lcdpublishing

> http://www.misterart.com/store/view.cfm?store=001&group_id=3700

Will check that out. DO you have any suggestions for a spray-on 
protection?  I would think a laquer would eat the film.

> A simple plug-n-play setup using drivers from here;
> http://www.cadcamcadcam.com/index.asp?PageAction=VIEWPROD&ProdID=11


Rats, current is too low for my needs.

> http://www.geckodrive.com/item.htbml?order_id=0&item_id=G320

The 320 is the one I believe I am going with, while still low on 
current (20 amps and I need 40), I am hoping it will work for me at 
the reduced current.  The mechanical gearing I am using should 
equalize the lower current as delivered by the Gecko.

Chris

Re: A CAD/CAM/CNC approach to case design/construction

2005-07-27 by derekhawkins

> DO you have any suggestions for a spray-on
> protection?

Krylon's crystal clear acrylic sprays work well. Very popular in art 
and photographic circles for this purpose. Careful, use several thin 
coats only, too much at one time and the toner will run. Never tried 
it with injet output but the same probably applies. Minwax's 
polyurethane sprays should also work, tried only the gloss, but it 
had a varnished look I didn't like.

> The 320 is the one I believe I am going with, while still low on 
> current (20 amps and I need 40), I am hoping it will work for me at 
> the reduced current.  The mechanical gearing I am using should 
> equalize the lower current as delivered by the Gecko.

Your maximum feedrate would basically determine your maximum current 
requirements. Other than reducing that, you could opt for higher 
voltage motors unless you've already speced for 80V motors.

Note that the Gecko 320 has a fixed encoder multiplier of 4X 
(standard quadrature feature of these encoders). This means that your 
software step frequency requirement will have to be four times higher 
than that required were there a 1X option. Depending on your 
software, encoder CPR and motor RPM, this can be an issue if the 
encoder is on the motor shaft.

--- In Homebrew_PCBs@yahoogroups.com, "lcdpublishing" 
<lcdpublishing@y...> wrote:
> > http://www.misterart.com/store/view.cfm?store=001&group_id=3700
> 
> Will check that out. DO you have any suggestions for a spray-on 
> protection?  I would think a laquer would eat the film.
> 
> > A simple plug-n-play setup using drivers from here;> The 320 is 
the one I believe I am going with, while still low on 
> current (20 amps and I need 40), I am hoping it will work for me at 
> the reduced current.  The mechanical gearing I am using should 
> equalize the lower current as delivered by the Gecko.

> > http://www.cadcamcadcam.com/index.asp?
PageAction=VIEWPROD&ProdID=11
Show quoted textHide quoted text
> 
> 
> Rats, current is too low for my needs.
> 
> > http://www.geckodrive.com/item.htbml?order_id=0&item_id=G320
> 
> 
> Chris