Neathawk Designs – “If You Think It, We Can Create It!”

One of the many signs created by Neathawk Designs

When the recession of 2008 hit, housing and land developers found themselves hit particularly hard. Lindsay Neathawk was a graphic designer for a land developer, and soon was impacted by the recession as well come 2010—and found herself looking for a job. Instead of standing still and waiting for a job to come to her, she decided to invest in her first CNC tool (a CNC Shark) and began a sign making business in her garage. Neathawk Designs was born.

Because she was using her CNC tool for hours on end, and milling PVC over long periods of time, she kept breaking her machine. She found she outgrew the tool quickly, it only took about 2 months. But she continued on with the tool and used it for about a year before determining she needed a tool that was bigger and a bit more robust. In 2011, after much research she chose ShopBot’s Full Size PRSstandard. As a part of being able to get up and running on the machine in a timely manner, she and her husband attended one of ShopBot’s Basic Training sessions on-site at the ShopBot facility.

Once they returned home to Williamstown, MA in The Berkshires, Lindsay started working with the VCarve software and building sign files. That didn’t last too long, though. Three months after using VCarve, she decided to switch to Aspire. Lindsay told us, “I was so excited about doing 3D work, that I had to move from VCarve to Aspire to achieve the results I wanted.” Her first 3D project was a sign design for a dentist that included 3D teeth.

The signs that jump started using Aspire for projects.

While Neathawk Designs gets the majority of their work via word-of-mouth, referrals, or repeat business, sometimes a project comes up because of who you know, not just what you know. In 2012, Lindsay’s husband, Ryan, was speaking with one of their neighbors, Dr. Donald H. Sanders, an archaeologist. He had moved into the realm of digital media and had developed software that takes digital photos shot with a smartphone and converts them into 3D computer models, which can then be used for interactive archaeological visualizations. At the time, he was working with Harvard University’s Semitic Museum on a reproduction of a ceramic lion that had been destroyed 3,000 years earlier in the ancient city of Nuzi, in ancient Mitanni, (now northeastern Iraq). Apparently Ryan had the utmost confidence in his wife’s ability with her CNC tool, and suggested that they work together on a physical reproduction of the piece. While she hadn’t done this kind of project before, Lindsay forged ahead. She cut a prototype from foam on her ShopBot and when the people at the Harvard Semitic Museum were shown the result, they were blown away. She was then asked by the museum to create a full-sized version, using the same technique, for display in the museum alongside the remaining fragments of the original.

The Nuzi Lion

In subsequent years, Lindsay and Ryan determined that they wanted to expand their shop. First came the addition of a couple of pieces of equipment that gave them the ability to offer their clients more. Their sign business continued to thrive. They then realized that their garage just wasn’t enough space for the business and moved into a larger, much more spacious facility. More room to move, more room for equipment, and as it turns out, more room for larger projects.

In the meantime, Learning Sites, Inc., the company founded and run by Dr. Sanders, had begun work on another project. The spoils panel from the Arch of Titus in Rome was being studied and re-colorized as a part of an exhibition “The Arch of Titus – from Jerusalem to Rome, and Back” for the Yeshiva University Museum. After exploring several options, the museum decided that having a full-scale replica of the important Roman sculpture would be the most beneficial way to display it in the exhibition. To enhance the experience, a digital replica and colorization that Learning Sites had developed would be projected over it. Learning Sites contacted their friends at Neathawk Designs again, hoping they could help as they had with the Nuzi lion. Lindsay accepted the challenge of recreating the Roman relief panel and got to work on the project that was going to consume her life for almost two months.

The final piece is 1.5’ deep x 12.5’ wide x 6.5’ tall. Quite a bit larger than the bed of her 4’ x 8’ ShopBot PRSstandard, but that didn’t stop her from figuring out a way to make it happen. She divided the full-sized piece into four smaller panels, then used Aspire to create slices of each panel, with the slices building one on top of the other to complete the final surface. Each panel is made up of nine slices which means there were 36 slices in total. Once the software work was done, it was time to put her ShopBot to work. In the beginning, Lindsay sometimes had her ShopBot running for 24 hours straight! After 49 days straight, averaging 10-12 work hours a day, the piece was finished. To meet the deadline, she had promised that she wouldn’t work on any other projects until the Arch of Titus panel was complete. By the time she completed it, she had 25 sign projects waiting for her attention.

When it comes to Neathawk Designs’ typical work, Lindsay’s background in graphic design and marketing have been a huge help. She still views what she does as graphic design and marketing, just in a different medium. Potential clients come in and discuss their needs with her and often think they then need to employ the services of a designer, thinking that Lindsay only does the physical fabrication of the signs. They are often pleasantly surprised to learn that Neathawk designs and makes the signs, which makes it much easier on them. She also likes to get the client involved in the design process from the very beginning. As she puts it: “They’re the ones marrying the project, so they should be involved in developing it.”

While Neathawk Designs is Lindsay’s full-time job, her husband Ryan participates in the business as well. He not only contributes ideas (which are often a helpful different perspective), he does some of the fabrication work as well, particularly in metals. One of his more recent contributions was building a plasma cutter from scratch. Although he has a full-time job as a general contractor, he’d like to eventually stop doing that and do work for Neathawk Designs full-time. They’re not quite there yet, but it’s not too far out of reach.


Yeshiva University created a video documenting the process and installation of the spoils panel of the Arch of Titus replica. You can view it by using the link below:

Video courtesy of Yeshiva University



Robota Soars the Skies with ShopBot

Robota’s Eclipse taking flight

While working for a military systems manufacturer, Antonio Liska developed a sensibility regarding unmanned aircraft (UAVs). He was of the mind that unmanned aerial systems could be utilized beyond military applications—functionality that extended into more commercial applications and where they could serve far more altruistic purposes.

When military contracts started drying up in 2009, Antonio decided it was time to develop his own pursuits in the realm of UAVs—and started his own business, Robota. He began with autopilot development and used it with ready-to-fly airplane kits. This is where a Handibot® Smart Power Tool entered the picture. Antonio purchased a Handibot and used it to modify the fuselage of each airplane. He created a jig so that he could move the Handibot along the length of them and make changes better suited to Robota’s needs. But unfortunately, the model of the airplane they were using was discontinued.

It was at this point that Robota began designing and producing their own aircraft. This was also when they made the determination that they were in need of a larger CNC tool so that they had the ability to prototype, build, and customize the components needed to create their UAV, the Eclipse. Because Antonio had been happy with the work he had been able to do utilizing the Handibot, he decided to purchase another CNC made by ShopBot – the ShopBot Desktop.

Robota’s Eclipse UAV

The materials they use their ShopBot for vary—from wood to plastics to aluminum to fiberglass. This also includes using it to create the molds for the foam bodies of the aircraft, motor mounts cut from nylon, and trimming out parts after being thermoformed. “Whatever we can put on the ShopBot,” Liska says, “we do.” And just because they now have a ShopBot Desktop, that doesn’t mean that the Handibot sits by idly. The portability of the Handibot allows them to place it on top of larger pieces sitting in a jig (like a wing) and carve/engrave directly onto the already fabricated piece.

Antonio Liska and Robota’s ShopBot Desktop

Antonio Liska cuts molds for a UAV with the ShopBot Desktop

Plastic mold for UAV being fabricated on the ShopBot Desktop

Aluminum being milled on the ShopBot Desktop

Manufacturing Technician, Antonio Medellin, uses the Handibot Smart Power Tool to cut into the edge of the wing of a UAV

Robota’s UAVs are not hobby drones, they’re intended for use in mapping and survey applications, particularly for large areas. It enables survey professionals, engineering companies, and construction companies to get survey grade precision for imaging (down to a few centimeters accuracy on a map) in large areas without having to walk it in its entirety. This not only saves time, but also keeps people from having to manually survey potentially dangerous terrain. For example, they have customers in Houston currently utilizing Robota drones to assess the storm damage caused by Hurricane Harvey.

Because they not only create their own software, but also the majority of the hardware components, they are consistently making updates and improvements as they work. Their ShopBot Desktop assists in this. Liska told us, “One of the reasons we have a ShopBot is because we can make changes quickly. We have the tools to make modification to our tools, so that as things change, we can respond pretty quickly.” While they use VCarve for some of their basic 2D work, they use Fusion 360 for the 3D parts. They find that Fusion is the better solution for the CAM (computer aided machining) of what they do with their tools.

Although there is still a lot of education needed regarding the difference between hobby drones vs. work-based/utilitarian drones, Robota continues their quest in providing real-world solutions for the survey and construction professionals that use UAVs to get their own jobs done with accuracy and efficiency.

To learn more about Robota, see their video:



Handibot at the Pilchuck Glass School

Iceberg glass vase in progress – on pipe after being rolled onto textured plate.

In August 2017, Brian Gillespie and Tara Broyhill were artists in residence at the Pilchuck Glass School. During session 6, “Exploration”, they explored how generative design and digital fabrication can inform the form and texture of glass in new ways. It was with this in mind that they packed a Handibot® Smart Power Tool into their car, drove a couple of hours north of Seattle, and went to “summer camp for grown-ups.”

To read more about Brian and Tara’s exploration, as well as see more photos, visit the Handibot blog.

The Evolution of an Idea

When ShopBot began preparing for this year’s World Maker Faire in New York, we determined that we wanted to showcase how ShopBot CNC tools integrate into a small scale manufacturing process. Then it was time to get the creative juices flowing. In this case, it was the highly caffeinated creativity of Bill Young. Enter the initial idea: A lightweight food tray that one could place food on, contains an opening to hold a beverage, and can be held in one hand while using the other hand to eat and drink–and that could be made for the cost of a hot dog at a food truck event.

Bill cut a prototype, complete with a logo V-Carved into the surface, on his full-size ShopBot out of plywood and brought it to the ShopBot offices to show it off. The intent of the tray is to use it when people are eating outside in an environment with limited (or no) seating and table space. For example–if you were to visit a food truck or were having a picnic, you’d have an easier time with all of your food and drink with the tray instead of trying to juggle it with both hands, and figure out some awkward way to hold something while you took a sip from your cup or took a fork full of food.

Bill Young’s initial tray design.

After a couple of us at ShopBot had an opportunity to hold the trays and get a sense of the comfort factor in holding it, there were some suggested changes and adjustments to experiment with on the next iteration of the tray. Should we make adjustments to the spot for the beverage? Do we need to add a support of some kind to keep the drink from falling through the hole if it’s of a smaller size? Should we add legs of some kind so that if one is sitting on he ground, they can put it down without it laying flat on the ground? What about a lighter weight material that is moisture resistant? Is the hole for your thumb to hold onto it in the right place and is it the right size?

Enter again, the creative mind of Bill Young and a new version of the tray. This time cut from sheets of expanded PVC, a material that is still reasonably lightweight, but also has durability. This latest version also had a removable support system/legs. Some more of us at ShopBot played around with the trays and looked at solving the securing of a drink if it’s smaller than the provided beverage hole. The use of a ponytail holder around a can of soda to stop slippage was experimented with (being that a lot of women/girls often have at least one of them on them or in their bag). What if we inserted a stretchable mesh or fabric to act as a sling for the drink? What if the legs of the tray folded up to make the tray flat again when not using them? While the group continued to brainstorm on this and other potential revisions to the design of the tray, we sought out some information from sources that could give us some genuine usability feedback: food truck owners.

Durham, being a particularly foodie town, has a wealth of resources when it comes to opinions on food related items. We took a few of the initial prototypes to someone that owns a high-end food truck that’s hired for special/private events such as wedding receptions, anniversary parties, corporate events, or graduation parties. Being an avid woodworker himself, he had an instant appreciation for the tray and its elegant simplicity. He also gave us a different perspective on uses of the tray. Being that there is limited space in the food truck, the trays would need to stack flat or up on a shelf so that they could easily be used, wiped clean, and stored again. He really liked the stand or “legs” but wanted something that was all one unit so he didn’t have to store pieces in different places on the truck and/or give instructions to customers on how to set it up. Being able to customize the trays for a special event, for a keepsake for the guests, is a win all day long. Being able to pre-produce trays that can then can be customized by VCarve engraving in small batches would give him a lot of flexibility.

We also shared the trays and stands with a friend of ShopBot who has a local industrial kitchen, along with numerous resources for food truck businesses, where food trucks use the kitchen to prepare their foods and that also contains a large event space. His reaction and ideas for the trays expanded further than what we’d discussed with others. To him, this was a great solution for being at the beach and needing a tray for snacks and drinks. He saw it as more of a “traveling” food tray that you’d keep in your car or with a lawn chair. That way it could be used at any event where a person would be hanging out for a while and need a place to set your food and drink down without it sitting directly on the ground. He also raised the concerns for making sure the tray wasn’t too heavy once loaded up with food and drink and wondered how a child or an older person might handle the tray, or how a disabled person might assemble and use it.

We returned from our local visits and feedback with a few new design challenges: could we add legs or a stand that would be out of the same material that would act as one unit and fold flat when not in use, use the ShopBot to manufacture the additional parts, and attempt to keep costs of production in check?

This is where ShopBot’s Brian Owen entered the arena and started working on an idea for the tray making use of foldable legs—so that a person can use the tray laying flat or open up the legs and use that added height when needed. He began experimenting with a system for the legs that didn’t consume a lot of additional material and could be assembled with additional parts that didn’t require specialty parts. What he came up with? A structure that involved some extra cuts into the tray (which, with a CNC, is a pretty easy task once built into the cut file), some small legs for the support structure, and rubber bands. Yes, rubber bands.

Not only did Brian’s adjustments work as legs to hold the tray, but with some additional minor adjustments, it also acted as a support underneath the tray for the drink in the beverage hole. We now had a product that incorporated the changes that made our food tray more multifunctional. Our next step was to see how well the tray functioned in an environment it was intended to be used in. This is where the employees at ShopBot got to be our beta testers—but also got fed a good meal and enjoyed being outside in the fresh air one late summer afternoon.

Using the CNC to cut all the parts for this tray was a huge success. It gave our design team a few restrictions that turned out to be key elements in the overall product design.


We’ve learned a lot along the way in the evolution of this project and it’s still evolving! Brian Owen has tweaked the design files to allow for faster and easier assembly, Bill Young continues to make tray variations, one dubbed the “winer” for a wine and cheese party (smaller tray, slot for wine glass stem), and we discovered that doing the VCarve engraving with a masking material applied first makes painting and finishing work much cleaner! With our project spec changes midway through this project, our cost per item did increase due to additional material used, cut time, labor, assembly, and overhead. So while we were looking to keep our cost per tray around that of a hot dog at a food truck event, we found it came in more around the cost of a cheeseburger, fries, and drink. Bill still hasn’t given up on the vision of the minimum viable product, “cost of a hot dog” version. We’ll be testing some of that one out at the Maker Dinner during the New York Maker Faire—everyone needs a place to hold their cup of beer while eating their plate of paella!

Stop by our booth at World Maker Faire in New York September 23-24. We’ll be showing the full production process in action.

Collaborations and Workshops, Bringing Fab Labs Together in Santiago, Chile

Fab13, the 13th International Fab Lab Meeting, was hosted in Santiago, Chile from July 31 to August 6, 2017. This year’s “Fabricating Society” theme was in action throughout the event. There were six strategic categories: city, housing, innovation and entrepreneurship, environment and energy, education, and decentralization–and each had clearly defined projects.

I was able to tag along with Sallye Coyle on this adventure and had the opportunity to participate in the conference, symposium, and the festival. We also visited a couple of University Fab Labs in Santiago that have ShopBot tools, did some ShopBot training, and did a tool tune-up at the Center for Innovation at Pontifical Universidad Catolica De Chile.

During the conference, presentations and smaller working breakout sessions happened daily, where attendees were active participants and took on specific roles/tasks to help move the six defined initiatives forward. Discussions included: Prototyping a Sustainable Future, Making New Economies, Decentralization– Mobile Fab Labs & Emergency Solutions, Foundations and Regional Networks, Fab City Working Groups, How to Make Spaces and Things: A Pedagogical Approach, and so many more.

The impromptu discussions and collaborations that extended beyond the scheduled events provided a great deal to think about. Groups from the US, Brazil, Israel, Peru, and Africa, to name a few, were working together to discuss moving forward on the six initiatives–as well as other ideas–well into the evenings throughout Santiago. We talked with the FabLat group at length about their project installed during Fab13 and about their plans for another collaborative project at Fab14. See the video about their project.

(Translated Video description below)

PABELLÓN LAT. is a project that was born as an initiative of the Latin American network of digital manufacturing laboratories. Its objective was to integrate Latin American countries and create a team committed to the development of the region and improving living conditions in Latin America.

The pavilion was placed in the context of the world congress of Fab13 digital manufacturing laboratories “fabricating society” in Santiago, Chile in August 2017.

To achieve this objective, the REGIONAL INTEGRATION LAT PAVILION was visualized by using wooden components cut by computerized numerical control (CNC) machines in a shape simulating atoms. When connected, the atomic shapes generate a larger molecular structure. Each of the atoms represents one of the countries that contributed to the project, which, when united with the each other, represent the Latin American network as a single molecule. In the process, the identity of the Latin American network has also been developed, which is applied to show the link between the 12 countries that have joined the project.

The manufacture of the pavilion was contributed to by several countries Brazil, Ecuador, Uruguay, and others. The pieces were transported to the event to be assembled in Chile along with locally made pieces, resulting in an assembled structure with materials from different countries in a united effort.

LAT PAVILION became the materialization of a collaborative and distributed effort among 12 countries of the region that united their ancestral identity with modern technology—and an incredible human team with a view to generating projects of high impact in the region.

Sallye and I brought along a Handibot® Smart Power Tool to show during the Humanitarian Lab Brainstorming and Strategizing Session. We shipped the Handibot in a plywood crate and brought along a zip tie connected plywood box (both designed by our very own Bill Young) to demonstrate how tools and other supplies might be transported for the Humanitarian Lab effort globally.


Handbot in tow, we talked digital fab, ShopBot, and Handibot throughout the week. The Carnegie Science Center in Pittsburgh, PA invited us to help with cutting parts for their workshop: The Sphero Robotic Rescue Mission, A Making + Coding Engineering Challenge; teaching leaders from other Fab Labs workshop ideas to take back and integrate into their programming. 

We held a raffle for one lucky winner to take the Handibot home. The winner, Dominique Torrin from New Caledonia in the South Pacific, now has the very first digital fab tool for his brand new lab. Can’t wait to see what fun things this group makes! Congratulations!


Of course, we had to take a couple days to check out the sites in Chile while we were there. We went from the middle of summer in North Carolina (90-102°F) to Chile’s winter (40-60°F). One highlight was getting to visit two of Pablo Naruda’s three homes. He’s known as “the Poet” in Chile and beyond, and we learned about his impact on the people and politics of Chile. Whether we were pausing for a bite at a street cafe in Santiago, climbing the steep steps in Valparaiso, or admiring the majestic snow capped mountains; we found Chile to be a vibrant country with a thriving culture that respects the past and visibly looks towards improving the future.

We are looking forward to participating at Fab14 which is scheduled to take place in July 2018 in Toulouse, France. The Fab Lab Festival will be held in different cities throughout France. The Fab City Summit in Paris will be held the following week. Take a look at this video for more information


Getting to know the amazing people involved in Fab Labs across the globe is an ongoing and incredibly inspirational.

ShopBot Joins the 2017 National Scout Jamboree’s Makerspace

One of the many campsite areas from the 2017 National Scout Jamboree

The 2017 National Scout Jamboree at the Bechtel Summit Reserve in West Virginia was a huge event for makers and an opportunity for 40,000 scouts and scouters to learn how much fun a Makerspace can be. The National Jamboree set up a large area full of tents called STEM Quest with opportunities for scouts to earn merit badges and discover multiple technologies. One of these tents was a MakerSpace tent set up by Cognizant that included many activities, such as drone flying, robot programing, sewing, silk screening, soldering, and CNC machining, to name a few. ShopBot sent a couple of guys to help introduce the scouts to CNC with two Handibot® Smart Power Tools and a ShopBot Desktop.

Throughout the 10 days of the jamboree, and with the help of several adult scout volunteers, almost 2000 scouts took the opportunity to make badges on the two Handibots that were brought to the event and using the FabMo app, Badger. There were also multiple opportunities to teach some of the scouts how to make a project that was a little more involved. Most of these scouts chose to make a name badge that they could wear on their uniform after the jamboree. The training to make these badges involved VCarve Pro for converting a raster image to lines and arcs, toolpathing, how to set up the tool and then cut. This was an amazing experience, it was a ton of fun to teach these scouts about CNC and see the smiles on their faces when they finished making something on their own, for the first time in most cases, on a CNC machine.

~ Reported by Gordon Bergfors

Prototyping and Production Across Platforms: Laser and CNC at Digital Fabrication for Educators, July 2017

Slide together steps prototyped and produced during July’s Digital Fab for Educators.


Traveling to Durham, NC from Baltimore, MD with his wife and elderly dog gave one of the July 2017 Digital Fabrication for Educators Workshop attendees, Frank, an idea of what to create during the workshop at ShopBot. The old girl (canine) had a difficult time getting into the back seat of the car, and helping her by lifting her hind end into the car seemed to cause her pain. So Frank decided to design and fabricate a set of slotted stairs that he could assemble without hardware.

Frank used SketchUp to design the steps. Since SketchUp is a 3D rendering CAD program, he could view the design from several orientations, as well as change the thickness of all linked components (like the slots) in one fell swoop. Plus, it is easy to import a SketchUp file (.skp) into VCarve Pro for machining in 1/2” plywood. Once he had all of the parts, Frank scaled them down so that he could use the Epilog laser to cut a prototype in cardboard. He then exported the vectors from VCarve Pro in .eps format to bring them into Corel Draw for “printing” on the laser cutter.


Cardboard model of car steps.


Frank talking to the class about his cardboard prototype cut on the laser cutter. Thank you to Epilog laser for loaning ShopBot a laser for the workshop.


Once he was convinced that the design would be stable and easy to assemble, Frank set about prepping it for machining on a ShopBot. The first step was to test that the slots were the correct size for the half inch sheets of plywood that were available in the shop. Sallye (the workshop instructor) helped him to create a test piece that could be fitted onto the edge of the plywood to determine what size to make the slots so that the pieces fit together easily and without too much slope.


Start with a larger rectangle that defines the total size of the test piece. For the slot sizes, create a series of rectangles of different heights that extend beyond the test piece. (See below for why the width of the slot test pieces extend beyond the test piece.) Toolpath the slot test rectangles as a pocket that goes about halfway through the test piece. Use “profile” to the outside to cut out the test piece. Remember to use the same bit and cut direction for the test cut that will be used for cutting out the final parts.


Clicking the solid box in the lower right corner of the toolpath screen will show what the bit will actually machine away. Note that the radius on the inside corners of the slots. By having the slot test rectangles extend beyond the actual cut out, the rounded inside corners will be cut off when the test piece is cut out, so the slots will fit on edge of the board.


A simulation of the resulting test piece. Mark the slot sizes with a permanent marker, and indicate which bit (size and geometry such as up or down spiral) and cut direction (climb or conventional) was used for future use.


The half inch Baltic birch available was actually a 1/2” inch thick, so the slot size did not have to be adjusted in the original CAD drawing. Frank used VCarve Pro to add dogbones to each of the inside corners to allow for a square edge to fit into it. Then, he laid out all the parts on the 4 x 8 sheets of plywood and set the toolpaths to machine with a 1/4” down spiral bit.


The closest that the spinning bit can get into an inside corner is the radius of the bit. Adding a dogbone to each inside corner creates space for a square corner to fit into the slot. Look under the “Fillets” icon to find the dogbone feature.


Watching ShopBot’s production tool with Automatic Tool Changer (ATC), vacuum hold down system, and dust collection cut out the parts is a group activity.


The actual machining on ShopBot’s production tool with Automatic Tool Changer and vacuum hold down system took a matter of minutes. After a little sanding, a group took the steps out to his car for a test run (as seen in the photo at the start of this blog post). Frank found he could assemble his steps in a minute and a half. The half inch plywood flexed a bit more than he would like for his 50 lb. dog, but another attendee, Kirsten, suggested that he use plastic drink cups as supports to increase the structural integrity of the wider steps. We can’t wait to hear (and see) how his pup likes her new stairway.

Below are more pictures of the projects completed and the friendships made during the 3 day workshop.


ShopBot Spotlight: The Stars Align for Syzygy Woodworks

syz·y·gy [siz-i-jee]


Astronomy: An alignment of three celestial objects, such as the sun, the earth, and either the moon or a planet.

Any pair of connected or corresponding things.

For most people, the word “syzygy” seems like something out of a foreign language dictionary. Primarily used in astronomy, the term refers to the lining up of multiple objects in space. However, it also can refer to any pair of connected or corresponding things. For Keith Larrett, the word has an even deeper meaning: his wife used it in conversation one of their first dates, and it stuck with him. So much so, in fact, that he took it as the name of his Palm Coast, FL woodworking business, and he’s been producing some amazing built-in cabinetry and CNC furniture projects for both local and out-of-state clients. 

A Built-In Client Base

Prior to going full-time with Syzygy, Keith spent over a decade installing cabinets in the Palm Coast area. In tackling all different kinds of installation situations, he became more and more interested in the design and brainstorming aspect of working with unique spaces rather than just hanging them, and eventually started doing some design on the side. Thankfully, the client base looking for design overlapped with those in need of installation, and after a while he found himself providing both.

As his client base grew from word-of-mouth and referrals, the possibility of full-time custom furniture became more of a possibility. Keith found himself becoming more and more involved with the planning, brainstorming, and design component of CNC furniture installation, which required more onsite measurements and working from pictures to figure out how things would work in unique spaces throughout homes and businesses. Eventually, he realized that with an upgrade in equipment, he’d be able to open up a whole new world of possibilities.

ShopBot and Cabinet Design

When looking for a tool that would allow for Syzygy to work full-time, it was very important that whatever he bought be compatible with eCabinets. Keith had gained some experience with the program over the course of the past several years, but he had some trouble finding a well-built tool that could withstand daily use and make the most out of the software. He was fully new to the idea of a CNC tool, but everyone he had spoken to had mentioned that it was a must for any woodworker’s shop. After asking around, the lone candidate was the ShopBot PRSalpha. He invested in a PRSalpha with 5′ x 8′ table with Automatic Tool Changer and immediately realized its importance to his business. Not only was it compatible with cabinet software, but it could handle sheet goods of every type, from MDF and plywood to plastic and acrylic.

built-in office cnc furniture

One of Syzygy’s most recent installations, a built-in office desk.

“When I first bought my PRSalpha, I thought it would do everything for me,” says Larrett. “But what I’ve learned since is that it’s even more important than that: it doesn’t do the work for me, it allows me to do work that wasn’t possible before, and do it with more speed and precision.”

Unique Process for Unique Projects

When it comes to difficult projects, Keith doesn’t shy away from trying new things: he often goes into a client’s space having little more than a vague idea of what they are looking for. In fact, his first client challenged to create a huge bookcase installation that filled a 20-foot high 4′ x 8′ foyer and had a layer of acrylic that one could actually walk out on! After going over to visit and take measurements, he entered his shop with a rough sketch, dimensions, and a few ideas.

Knowing that he could cut all of the parts and make adjustments on the ShopBot made things a little easier for Keith. He was able to machine the intricate designs needed for all of the detail work, including the Horace Mann quote that appeared on the header into the main home: “A house without books is like a room without windows.”

A job of this scope was something that Keith had never done before, but as he puts it, he “figured it out as he went”, since he was able to carefully engineer the entire installation just as if it was kitchen cabinetry: by making sure everything is properly mounted and built into the space, there’d be no worries that it would be done right. And any prototyping could be done on the ShopBot before it was officially installed.

horace mann quote on doorway

Still, with all of his confidence and experience, it was his brief time as a professional skydiver that came in handy the most once installation was completed.

“I’m not going to lie,” laughs Keith. “That first step out onto the acrylic floor was kind of a ‘leap of faith’. But I’m confident that everything in that room is there to stay.”

syzygy woodworks cnc furniture bookcase

Keith Larrett demonstrates the support of the clear acrylic floor.

Keeping the ShopBot Busy

Thanks to his great work, reputation, and huge fan response on social media, Keith has no problem finding work these days. As if running a full-time furniture business wasn’t enough, however, there are still times when the ShopBot isn’t being used. During these hours, while Keith draws up plans or uses the woodturner, he offers CNC routing services to his local Palm Coast community. This way, as Keith says, “the ShopBot stays as busy as I am”.

CNC, Skateboards, and Sunshine: ShopBot at Maker Faire Bay Area

This last May, ShopBot headed to San Mateo, CA for Maker Faire Bay Area, the West Coast’s premier gathering of makers, tinkerers, creators, and thinkers. While the event’s intensity and creativity was familiar to past Maker Faire events, there was also a distinctly Californian vibe to all of the proceedings, from the consistently beautiful weather to the intense arts and entertainment-driven crowd.

bubbles at san mateo maker faire 2017

Sunshine was in no short supply at this year’s event, making for some wonderful outdoor displays.

The ShopBot booth was the first to greet Makers as they entered the gargantuan Warehouse 2, which housed all of the event’s fabricators, craftspeople, maker spaces, and science displays. At the booth were two Handibots cutting badges with the FabMo Badger app, and a DesktopMAX cutting skateboards, which were a huge hit at New York Maker Faire back in October of last year. In addition, the ShopBot team was joined by Russ Wade, who drove all the way from Chiloquin, OR to help out and show off some of his fantastic O-scale model train buildings and boxcars cut on a ShopBot.

Interactive Nametag Cutting with Badger

One of the most rewarding and engaging activities at the ShopBot booth was showing off the Handibot’s capabilities to Makers of all ages with personalized name tags cut on the FabMo Badger app. Similar to SmoothSketch, which turns an image drawn on a tablet or device into a cut file, Badger scales the image down to fit on precut colored badges made exclusively for the event. Each one has a small magnet stuck onto the back which not only prevents people having to deal with pinning them to fabric, but also holds it in place in the jig while the tool cuts.

The magnetic backing holds the badge in place while the Handibot cuts.

Visitors to the ShopBot booth were able to choose from one of three colors and two shapes, then were able to draw or write with their finger on the provided tablets. Upon submitting the file, the FabMo control software did the rest of the work and sent the job to the tool wirelessly. Makers of all ages were entertained watching their quick designs turn into permanent carvings, with some even returning later to show their friends.

Onlookers watch as a young Maker designs her masterpiece. This group returned several times to spread the word to friends.

CNC Skateboards on the Desktop MAX

In addition to the two Handibots, the ShopBot team brought along a Desktop MAX, which cut several Skateboards over the course of the three-day event. Building off of a method conceived by Bill Young, the MAX was set up with a jig designed to hold the material. The boards themselves started off as three layers of 1/8″ baltic birch glued together, then placed in a specially designed clamp to provide the curves as it dries. For MFBA 17, the ShopBot team brought along six pre-glued, ready-to-cut boards.

cnc skateboards at maker faire bay area 17

Screwing the ready-to-cut board down to the jig on the Desktop MAX.




#ShopBot at #MFBA17 cutting #skateboard decks on #DesktopMAX!

A post shared by ShopBot Tools (@shopbottools) on


Other Happenings Around MFBA ’17

maker faire cupcake car

One of many “cupcake cars” weaves its way through the crowd.


The spirit of creativity and collaboration was in full force all around the event. From small tinkerer’s shops all to the way to tech giants like Google and Microsoft, everyone came together in the spirit of making cool stuff. It was great to take part in an event with such a passionate, inquisitive, and unique crowd. We can’t wait for the next one!



Digital Fabrication for Educators: Your Place or Ours

Whether it takes place at ShopBot, or on site, a 2 – 3 Day Professional Development workshop gives teachers a chance to hone their skills with digital fabrication machines. Educators starting at all levels, from newby to someone with a year or more experience running their ShopBot CNC router, end up with new techniques that they can introduce into their lesson plans and curriculum.

After leading Digital Fabrication for Educators (DFFE) workshops at ShopBot in May and June of 2017, I flew to Spokane, WA to work with teachers from two high schools in Mead, WA. Both are Project Lead the Way schools, so two of the teachers were well-versed in Inventor 3D Rendering CAD software. They also have laser cutters and 3D printers at their disposal. The other teachers were not so computer-savvy, but were experienced woodworkers and builders. All of the teachers, Spokane natives, were passionate about exposing the kids to the possibilities available in CTE and STEM programs.

The wood shop at Mt. Spokane High is beautifully organized where everything has its place. Bill Patrick, the lead teacher at Mt. Spokane, also teaches an after-school welding class to expose the kids to another skill. Girls and boys participate, although it’s still about 75% boys.

Bill Patrick welded this Cowboy from old tools salvaged from a shop being shut down

There is a list of topics to be covered during each Workshop, but the order of presentation flows according to the skills and interests of the participants. A “newby” with virtually no experience in CAD/CAM and running a tool can work alongside someone who has had a CNC router for 12 years, but now wants to move into designing and machining in 3D. At Mt. Spokane, the session started with a tune up of their newly assembled PRS standard with a 2.2 HP spindle. With the ShopBot Troubleshooting guide in hand, a few wires were switched around, a few set screws tightened, and a few bearings and proximity switch targets were adjusted until the ShopBot was running smoothly. The first group VCarve Pro CAD/CAM project was a file to surface the sacrificial board with the 1.25” surfacing bit.

The first step for surfacing the ShopBot table is to run a “cross check” across the sacrificial board to determine what depth to machine the entire table.

Then, a pocketing routine (raster) levels the sacrificial board.

The first set of personal projects were signs VCarved in a piece of Melamine found in the scrap bin. Each person designed their own, then we machined them with the 60 degree V bit found in the ShopBot starter bit kit. Because each font was different, the look of each sign varied even though the 60V bit and the Engraving toolpath was the same.

A variety of signs created as a first project at Mt. Spokane High School. Five of the signs were all carved with a 60 V bit (displayed on the sign for Dad’s Shop.) The different in cutting depth and look is related to the different fonts used in the design of the sign.

Mt. Spokane also ordered the signmaker’s bit kit (second 60V bit swapped out for a 120V), so we had the opportunity to see how the same font would look machined with a different V bit (60V, 90V and 120V.) Since VCarve Pro uses the geometry of the bit to determine how deep to plunge the bit to fill the space of the design, letters carved with a 90V bit are shallower than those carved with a 60V bit. When using a 120V bit, the carving is shallower still.

The same font will be carved at a different depth with a different V bit. While a 60 V is a better choice for small, detailed engraving, a 120 V is the better choice when letters are large. The light from the letters will reflect out to the viewer rather than into the recesses of the carving. A 90 V bit can be used for engraving, and also for mitering the edge of the material to make a mitered box.

By midmorning on Day 2, each teacher was deep into following their own path. While we would gather for a brief lesson on a particular topic, my role became that of a guide helping each teacher pursue their particular goal.

Too busy working to break for lunch.

On Day 3, I left the teachers deep in conversation in how they would organize their classes for the next year. How about: give each student a sheet of plywood, and score them on the designs they create as well as how efficiently they use their material?

Teachers discussing how to integrate the Step Stool Project downloaded from the ShopBot website into their classes for next school year.

Peruse the photos below to see some of the projects created during the DFFE workshops, both in Washington and at ShopBot. The July Workshop is filled, but check the Events page on the ShopBot website for more dates to be added in the Fall.

This topographic map of the Mt. Ranier region in Washington State was generated as an .stl file, then imported into VCarve Pro and machined with a .125” ball nose bit. Because the material was insulation foam, there was no need to run a roughing pass.

Sign incorporating V Carving and 3D medallions from ClipArt in VCarve Pro

One of the topics is to show how the same design (2D or 3D) can be machined or printed on multiple digital fabrication tools.

ShopBot 2017: Same .stl file printed on a 3D printer and machined in wood on a ShopBot CNC router. It took longer to 3D print than to machine on the ShopBot.

Same 2D design file Engraved on a ShopBot and cut on laser cutter. Keeping a record of the results is a valuable lesson.

Teachers from Oregon used their Perkins grant for Professional Development to return to ShopBot after having used it in the classroom for a year. They reversed-engineered a spring-joint-box designed by Randy Johnson

Spring box completed and VCarved on the Handibot. No need to shop for a birthday present.

New users from Fanshawe School of Art and Design (Canada) got experience on the laser cutter and ShopBot.

Trying out the Handibot