TechShop DC/Arlington served as a great host location for the first ever DC-Arlington Camp ShopBot. Situated across from Reagan International Airport, a large and varied population utilizes the space and tools. And with three different models of ShopBot machines and array of other machines their members are not lacking in digital fabrication resources. One can tell that Gadsden Merrill, General Manager, and his staff work tirelessly creating an energetic environment.
The ShopBot team comprised of Sallye Coyle, Reggie Riddit, Thea Eck, Bill Young, and guest presenter Andy Pitts. Attendees drove in from as far away as Eastern PA and also from Baltimore and the surrounding Virginia communities. Experience ranged from absolute beginner to professional user with years of CNC practice, many types of material cut, and multiple Camps attended. And being at a makerspace, curious TechShop members popped in and out all day.
Sallye began the day discussing CNC and CAD/CAM along with the cache of digital fabrication tools now available to the average maker that aid in prototyping or embellishing projects. Thea then lead the group in several presentations including highlights of Vectric’s new Aspire 8.5 and how to calculate the dreaded feed rate and speeds for a project. Sallye showed some hidden gems in the SB3 software, which are often overlooked or not fully understood. Lunch gave everyone the opportunity to mingle, look around TechShop’s studios and talk one on one to ShopBot staff.
Following lunch, the Show and Tell session offered a few volunteers the chance to present their projects. Andy Pitts then launched into the afternoon presentations explaining how to set up a CAD file and then machine a two-sided bowl using Aspire software. Though simple upon first inspection, this complex bowl shape utilizes multiple two-rail sweeps and 45° 3D machining techniques. Sallye and Thea followed up with two presentations on 3D machining: 3D scan to 3D machining and practices in 3D designing/machining starting with the basics such types of bits and understanding stepover rates.
Bill Young discussed and then demoed FabMo, a new development currently used to operate the Handibot. Bill chimed in throughout the day with his expertise on a variety of material, software, and machining topics. The final presentation, machine maintenance and troubleshooting, got everyone out of their seats and crowded around TechShop’s PRS Alpha 4×8.
Like many Camps, the day sped by. Often times conversation came back to pricing items and calculating costs: electrical costs, material costs, production vs. custom items, how much to pay oneself and working with clients. Everyone seemed to gain new insight, some ‘hidden gem’, personal to them that will hopefully make machining or designing a little easier.
Thank you to the TechShop DC/Arlington staff and to the attendees for spending their Saturday with us.
The Wood shop. Each studio includes an array of tools, both traditional and digital.
TechShop DC/Arlington has three different ShopBot models
Andy Pitts explained the jig he used to register his two-sided bowl.
Bill Young showed off the Handibot.
Friends from 5 Continents sharing one last evening at SZOIL after Fab 12 in Shenzhen.
The Location: This year’s gathering of the International FabLab network took place in early August in Shenzhen, China. About an hour from Hong Kong, Shenzhen is a new city, grown up in the last 25 – 30 years from a fishing village to a modern industrial and commercial center. Except for the signs in Chinese characters, the view from my room on the 22nd floor of a hotel in the financial/convention district looked more like an American city than many international cities built on top of older civilizations: traffic was organized in proper lanes, turns signals flashing, horns blaring. Shenzhen’s location close to Hong Kong, the numerous factories to manufacture whatever it is you need, and the amazing network of creative spaces around Shenzhen made it the perfect location to hold the meeting.
Those FabLabbers with a bent towards creating their own could fill a suitcase with motors, drivers, boards, cables, or purchase real or knock off phones, cameras, projectors, and watches in the electronics markets. The shopping malls carried name brand clothing, shoes and purses from around the world, as well as motorized carts in the shape of animals for the kids to ride around the mall. Many malls had DIY sections, with build-your-own music boxes, pottery wheels, and painting classes. Grocery stores had Lays Potato chips bags with funny faces on them, cans of soda with the name in the familiar Coco Cola font as well as Chinese Characters, Dragon fruit, and chickens with head and feet still attached.
It seems that the crane is the national bird.
Adam (New Zealand) and Frosti (Iceland) explore the electronics market.
Traffic in Shenzhen is orderly, though horns are in constant use.
Sunday afternoon at the mall is a family affair
The Meeting: The annual Fab gathering is an important vehicle for building and maintaining the network of FabLabs. It is also a celebration honoring the graduates of Fab Academy, the 6 month long course based on MIT’s “How to Make (Almost) Anything.”
Mornings were filled with reports on the doings of FabLabs around the world, and announcements of interest to the greater community. And there is always Fabbercise, which can have its own share of familiarity and hilarity.
Motorized scooter created at FabLab Hamamatsu, Japan. A ShopBot was used to cut out the MDF parts of the body.
Solidworks introduces an add-in for Fab Modules, Neil Gershenfeld’s software for running digital fabrication machines in the lab.
Fabbercise, led by Walter and others of the crew from Peru, weaves the audience into a web of laughter.
Afternoons brought options for workshops and sessions. Want to use a laser cutter to create hats or lamps? There’s a workshop for you. Want to discuss topics in education or humanitarianism? There’s a session for you. Want to catch up with old friends and make new ones? There’s plenty of time to connect, collaborate and share. Evening meals and after gave more opportunities to learn what is happening in FabLabs around the world. There was even the opportunity to see how products developed in a FabLab can be brought to market when 3NOD, one of the event sponsors, hosted a fabulous evening at their headquarters.
Lanterns demonstrate Chinese traditions, plus laser cutting and circuits for the battery-powered lights.
Bas (Iceland), Ohad (Israel) and Jean-Luc (USA) connect over workstation for creating new digital fab tools.
Ohad (Israel) and Wendy (New Zealand) show off hats made in their textiles workshop.
HotPot with Katy and Jennifer from FabLab Santa Clara
Dinner hosted by 3NOD.
Products brought to market via 3NOD, Shenzhen.
The focus of Fab12 was FABLAB 2.0, the ability of a FabLab to use its own digital fabrication tools to produce a fab lab and to produce the manufacturing machines of the future. Since the Handibot (www.handibot.com) was inspired by work of MIT students under the direction of MIT Professor Neil Gershenfeld, Center for Bits and Atoms ( www.cba.mit.edu ), it seemed only proper that a Handibot traveled to Shenzhen to take part in the festivities. Others brought their version of a digital fabrication tool created in a FabLab. Jens Dyvik used the ShopBot in the Shenzhen Open Innovation Lab (SZOIL) to fabricate parts for his VBird parametric CNC, and Steven Sui made his multipurpose CNC machine with GCC products such as the laser cutter and CNC machine. Nadya Peek offered workshops on how to create digital fabrication tools from cardboard kits and component motors and rails.
Handibot’s view from the hotel room on the 22nd floor.
Jens Devyk (Norway) conducted a workshop on using a large format CNC (ShopBot) to create a parametric CNC from plastic and MDF. You can see a video of Jens’ VBird CNC machine and software here.
Handibot with Steven Sui’s U-Bot, a small CNC with the option to change out a 600 rpm router with a laser head.
Detail of rack cut on ShopBot for VBird parametric CNC.
The Symposium: Friday’s symposium, open to the public, addressed 4 topics that scaled from the individual to the civilization.
- Systems That Make Systems
- Businesses That Make Businesses
- Organizations That Make Organizations
- Civilizations That Make Civilizations
The Fab Festival: The weekend event, open to the public at the Civic Center, was a celebration of all things Fab.
FabLabs in Peru are working with indigenous people to retain knowledge about such skills as weaving and furniture making. There is also a floating FabLab on the Amazon River.
FabLabs in India range from those at an Engineering University in Mumbai to an Ashram in the country that emphasizes project-based learning. Projects include how much it costs to raise animals, or create machinery that enhances lives. In Kerula, there will be 20 mobile FabLabs distributed around the province, each with a ShopBot Desktop.
Jens’ finished CNC at Fab Fest.
FabLab Barcelona has a strong program in textiles. Barcelona has a commitment to creating a “smart city” in which there are multiple, localized fab labs so that people can create what they need rather than import goods and export trash.
Folks from France and India at Fab Fest. Fab 13 will take place in Santiago, Chile, and Fab 14 in Toulouse, France.
ShopBot Sallye at Fab 12:
ShopBot and FabLabs have had a strong relationship for a number of years. ShopBot is a CNC of choice on the official FabLab buy list, so attending the Fab meetings is an opportunity to keep up with the exciting advances that those who participate in the FabLab network are making, offer training and tech support where needed, and learn what ShopBot needs to pay attention to in order to better serve the community. After 6 years of working with FabLabs, I feel that I have a growing network of contacts that works both ways. If someone has a question, they have my direct email and a cell phone number to call. Likewise, if a ShopBot user or ShopBot Tech Support needs a local representative to serve as “boots on the ground”, I have an idea of who has ShopBot experience that we can reach out to. Our plan is to expand that network and make it more accessible…look for an update to the ShopBot website in a few months.
It is always a bit surprising when someone refers to ShopBot as a “vendor”. We think of ourselves as friends and colleagues who just happen to manufacture an amazing CNC machine. Arriving a few days before each meeting is an opportunity to make new friends, pay attention to how people are actually using the machines, as well as to make sure that the local ShopBot is in proper working order for the meeting. For Fab 12, the ShopBot at SZOIL was mostly assembled, but Francisco S (Beach Lab, Sitges, Spain), Vicky (SZOIL) and I spent several hours resolving some Control Box/Spindle issues before laying down the support and spoil board. Since Francisco will be one of the trainers going to Kerala, India, to help with their deployment of 20 mobile FabLabs, he got some hands-on experience with hardware and software. Vicky, Fab Manager at SZOIL, began to take ownership of her ShopBot when she used a ratchet wrench for the first time to tighten the hardware for the support board. We ended the late night by taking a 3D scan that Vicky had created for printing on the 3D printer and machining it on the ShopBot.
With each international trip, I learn a bit more about how ShopBot is used outside of the US. Some lessons are not related to the ShopBot itself, but point out differences in the operating language of the computer, or electricians deciding to run the power to the control box in a way that does not conform to the specs of the tool. It can be a lesson about the types of material available locally. For example, in Shenzhen, there were two different kinds of sheet goods available in the lab. While both were referred to as “plywood”, they had very different characteristics. What I would call “plywood” is made up of thin layers of wood laid down with the grain rotated 90 degrees at each layer (ply). It is less resistant to changing size as the humidity level changes, and maintains a certain level of structural when dadoes or slots are machined into it. Sheet goods that are made up of long strips of solid wood glued up and covered with thin veneer may be more consistent in thickness than plywood, but it can lose its structural integrity as soon as the thin veneer has been machined through. I have never seen this type of sheet good in the US, but have now found it in Japan, Egypt and China.
Vicky, Fab Manager at SZOIL, tightening down the ShopBot support board.
Vicky’s first project with the ShopBot. She added bunny ears to the original .stl created from a 3D scan, then carved it on the ShopBot with a .25 ball nose bit. See our previous blog entry for the process to convert a 3D scan to a 3D ShopBot carving.
With “plywood” (above), thin layers of wood are peeled off of a log, laid down flat and laminated together. One does not have to pay attention to the grain of the sheet good when assembling cabinets or tables, since the grain of each “ply” is alternated 90 degrees to reduce the effects of changes in humidity level on size of each component.
The second type of sheet good is made of up solid strips of wood that are glued up the length of the board. Note the growth rings on the edge of the board. Only a thin layer of veneer adds strength to the glue up. Creating a dado or machining a hole/slot in the material could result in compromising the integrity of the sheet good because it could weaken where the strips are glued up.
There’s too much to talk about for me to put it all in this blog. Visit the Fab12 website, and look up Fab Foundation, Center for Bits and Atoms, and FabAcademy for more information on the wonderful things that are going on with the 1000+ FabLabs around the world.
From the time we first started, sharing has been an important part of ShopBot’s DNA. The files to build a ShopBot were originally released by Ted Hall as shareware and there have been a steady stream of project files available since then. The fabrication files for one of my first projects, “Honey’s Canoe,” have been available in various forms for 20 years, and are thought to be the first DIY CNC project to be shared publicly. Unfortunately, the infrastructure for sharing wasn’t quite up to the job in those days, so for the first couple of years we had to send all our files by mail on floppy disks!
We all learned to share in Kindergarten, it’s one of the most valuable things you’re taught. If you had a cookie and gave half to your friend, you’d be a better person for it. When you got older you might share a book or tool by lending it to someone. Sharing was easy, first the thing was yours and then someone else had it. You might get it back, but you couldn’t both have it at the same time.
Sharing became more complicated when things became digital. You could share something and still have it! Since the cost of making a copy of a digital file is functionally $0, you would think that sharing something you created costs you nothing. To do it right though there is a cost: a cost in time. Here are some things to think about when you are considering sharing a project:
Let me start by saying that I AM NOT A LAWYER and that this is just a layman’s understanding of a very complicated subject. Do your research, there are lots of resources on the web including the Creative Commons website.
With that out of the way, even though you may think you are sharing a thing—a chair, a table, a sign—what you’re really sharing are the files that describe that thing. The photos, CAD files, CNC part files, everything that tells what it is and how to make it. In the early days, we just made files available and basically said “have at it,” thinking that was all we had to do to make them useful. In the US and most of the rest of the world, all your files have been automatically copyrighted without you having to do a thing. No one can really use them until you add an “open license” that spells out the conditions that you place on using and distributing those files. This protects anyone that uses your files and prevents you from coming along in the future and saying “You didn’t have permission to use my files.”
Because of this automatic copyrighting, you have to assume that a file is protected by copyright unless an open license is attached to the file in some manner. It varies with the license, but generally there is either a file included with a project download that contains the terms of the license, or there’s something describing the license that you have to agree to before you download the file—and that license has to accompany the files any time you share the original files.
The Creative Commons folks do a great job of explaining how their licenses work, but here are a couple of terms and options that you should consider when deciding how to license your project files. Be aware that you can mix and match them to get just the combination that suits you :
Public Domain: You are giving the files to the public and anyone can do whatever they want with them.
Attribution: If someone shares your file they have to give you credit.
Share-alike: Any copies or modifications to the files have to be shared with the same or similar license.
Non-derivative: Anyone using the files can modify them for their own use, but can’t share their modified version and only reshare your original files.
Non-commercial: Your files are available for personal use, but can’t be used commercially without permission.
I know this is complicated and can be kind of a pain, but this licensing business is really important to understand before you decide to share files. Now, on to the nuts and bolts of sharing…
Files and formats:
The whole point of sharing projects is for them to be usable by someone else, and your job is to make it as easy as possible for people to fabricate your project. That means including files in formats that make it easy for the largest number of people.
We all love Vectric software and ShopBot includes it with all tools, so including those file formats is probably the most helpful. They let the end user make modifications to both customize the cutting to fit their particular tool and cutting style, and to make the project better suit their needs.
There are, however, ShopBotters and Handibotters that …gasp!… might not use VCarvePro or Aspire, or haven’t kept their copies up to date. That’s why we also recommend that you include an additional format or two—for those folks. A common vector format like .dxf , .dwh, .eps, .ai, or .svg works well for 2d cutting, and .stl is pretty universal for 3d models.
What about ShopBot .sbp files? It’s certainly helpful to include them and they make a lot of sense for things like Handibot projects where all the tools are the same size with the same cutting capabilities. If you include ShopBot files though, try to make sure that the cutting speeds and pass depths are on the conservative end of the spectrum.
Creating instructions is a lot of work and not much fun, but there’s some information that people just need to know. Details like materials, bit size, and any extra supplies that are needed. So at the minimum, please include a readme.txt file that includes that information and hopefully a little about yourself and how someone can contact you with praise (and questions). For anything but the simplest projects, including a little more complete set of instructions—maybe with some pictures—will be very helpful. And just like design files, use formats that are universal and accessible like .pdf and .html.
Storage and Updating:
Very few designs and projects are static, and almost all (hopefully) improve over the years. Keeping the online version in sync can be tough, but is really important. Lots of projects including Shelter 2.0 and Handibot use Github as a “repository,” but in general it was designed for software projects and is pretty tough for many people to use. DropBox is another option for storing and sharing files, and there are lots of tool-specific sharing sites like Handibot.com.
We all think we come up with project designs as a flash of inspiration and brilliance, but in reality they are almost always a composite of ideas that you have seen over the years. It’s often hard to place exactly where that inspiration came from and we all suffer a little from kleptonesia, defined in the Urban Dictionary as “(n.) condition characterized by forgetting the source of a stolen idea,” but it’s always better to err on the side of giving too much credit rather than not enough. If someone or something inspired you, make sure that you point that out!
Please don’t let all of this discourage you from sharing the things that you do. My intention is to make sure that when you do share files and projects that they are really useful to the end user, because that’s what it’s all about!
On a recent Professional Development session (PD) at the Chevron FabLab at California State University Bakersfield, Caroline McEnnis and Sallye Coyle of TIES (www.TIESTEACH.org) spent three days working with teachers, interns and staff to give them more experience with the digital fabrication tools and electronic components available in their Lab. Caroline had the attendees use a Kinects to scan themselves in 3D, then had the 3D printers print out tiny plastic versions of the scans. Later, Sallye showed the teachers how they could do more than print their 3D file (.stl) on a 3D printer. She had the teachers bring the models through VCarve Pro to create files that could be machined in wood on a ShopBot CNC.
3D printers printing heads scanned with a Kinect while teachers work on another project
Three of the scanned faces on a 2 x 6 board after running the roughing phases
Finished model with the original. Resolution was determined by the resolution of the scan, how the .stl was scaled from the original, and the size of the bit to carve the file (.25″ ball nose).
This is not a full tutorial, but an example of the steps we went through to machine the images in 2″ x 6″ boards. What could a teacher do with this? How about creating a totem pole with each student’s image as a class project? What can one teach about history and culture by studying totem poles? Are the more important images placed at the top of the totem pole, or at the bottom?
- Create the scan: The Internet has information on how to connect a Kinect to a PC to create a 3D scan. Here is one option. Virtually any 3D scan that creates an .stl would be appropriate.
- Bring the .stl into VCarve or Aspire (NOTE: version of VCarve Pro must be 7.5 or later):
- The HELP file in VCarve and Aspire is excellent; please refer to it in detail. The HELP is bookmarked, so when you click on the item you are interested in, it will go to that page.
- By clicking on the MODELING tab at the bottom of the left hand screen, you will see the options for working with a 3D model or component such as an .stl.
- When you import a component, you can choose what orientation to import the data. Keep clicking until you have the front view of the scan face up in the material.
- Change the view to the side view, and slide the bar until you have most of the image that can be machined from the top down (no undercuts). Delete the data below zero if you are only going to machine the face. If you want to do 2-sided carving, create both sides then separate the two 3D components for machining separately.
- You can only import one .stl at a time into VCarve Pro, so you may have to open a separate session of VCarve Pro for each face. As long as you know where to place them on the board, you can then machine them as needed (try putting a rectangle where each of the faces would go. You can then copy a vector or component from one session of VCarve/Aspire, then paste it into the same location on another session).
- Lay out the components on the virtual board, then toolpath them
- In the image below, the first of three 3D components laid out on the virtual representation of the board measured 24″ in the X (arbitrary length) x 5.5″ in the Y x 1.5″ in the Z (standard measurements of a 2″ x 6″), with the Z zero set to the top of the material. The component was placed in the center of a rectangle that was placed on the board. A second rectangle was also placed on the board to mark the location of a second 3D component.
- The height of the model was reduced to fit onto the thickness of the board. A model that has been flattened so that it keeps the features of the full 3D but would not be as thick as the original when viewed from the side is called bas (pronounced “baa”, French for “low”) relief.
- Select the rectangle surrounding the component and set the roughing pass. In this case, a .25″ end mill bit was used for the roughing passes. The screen below shows both 2D and 3D views. The 2D (left view) shows the placement of the component surrounded by a rectangular vector. The 3D (right view) shows the 3D rendering of the component with the roughing passes overlaid. The CAD menu screen (left side) and CAM menu side (right) are also shown. The 3D toolpathing options are circled.In this first sample for the 3D finish pass, two bit options were tested (virtually). While the .125″ ball nose bit would give more detail, it would take more time to machine than would the .25″ ball nose bit.
- Create two toolpaths, one for each bit. The use the icon that looks like a clock to see the estimated time for each of the toolpath options.
- Use the Preview icon to look at each of the toolpaths. Remember to reset the preview in between testing the toolpaths. This particular model does not really need the detail from a .125″ bit.
- Save the roughing and finish toolpaths (use the “floppy disk” icon)
- Save the roughing pass separately from the finish pass.
- Give each toolpath a name that you can remember later (you might include name of person scanned, roughing or finish pass, type of bit used, etc.).
- Do the same for each of the other faces
- Prepare the board for machining on the ShopBot
- Photo below shows board after faces completed how the hold down was placed outside the area of travel for the machining.
- The board was placed on the table so that the bit would not go outside the range of travel in the Y-axis (board moved away from the long edge of the table).
- Holes for screws to hold down the board were drilled before sheet rock screws were screwed through the board down to the sacrificial board under the 2 x 6. The length of the design area was measured (24″), and the screws placed outside that design area. See red oval for placement of screws at the top of the board.
- The X and Y axes were zeroed at the point where the first face would be machined to further ensure that the bit would not hit a screw while machining the file. Arrow points to where bit was positioned at place where file would start, then the Z2 command (or button on keypad screen) used to set that location as X and Y zero (0,0).
- Run all three roughing passes
- Run each of the ShopBot (.sbp) files that use the .25″ inch endmill to rough out the faces, one after the other
- Change the bit to the .25″ ball nose bit and do the finish passes, one after the other
- If necessary, use the scroll saw with a blade (or the band saw) to cut the faces into separate blocks
Other options for using 3D models:
- Take the file through 123Make to turn a 3D model into 2D build plans. Photos below show a 3D model of a boat “sliced” and machined in wood on a ShopBot and in acrylic with an Epilog laser cutter:
- In the example below, a CT scan of a duckbill dinosaur skull was taken through Rhino, then Aspire CAD/CAM software and “sliced” into 2″ thick panels of pink insulation foam which were machined on both sides. The sinuses and larynx were printed on the 3D printer, the whole thing reassembled, and a Ph.D. student used it in her dissertation:
Larry Sears and Sally Zlotnick Sears think[box]
is arguably one of the largest and most dynamic maker spaces in the country. think[box] is located at Case Western Reserve University’s Center for Innovation and Entrepreneurship, and provides a space for anyone – students, faculty, and alumni and members of the community – to tinker and creatively invent. Housed in a 7-story, 50,000 square foot facility, with 3 floors occupied and more to undergo renovation soon, this $35M project is one of the largest university-based innovation centers in the world. By numbers, think[box] receives over 5000 visits each month!
I recently spoke with Marcus Brathwaite, a Lab Technician at think[box]. One of Marcus’ responsibilities is to train people in use of the full size ShopBot tool in the maker space. Marcus graduated from the Cleveland Institute of Art in 2013 with a B.F.A. degree in Ceramics.
As a member of the team his mission is to bridge the gap between science and the arts by facilitating and developing art experiences in and around think[box]. His artwork investigates the past, present and future of human relationships to technology. Marcus said, “I was first exposed to the ShopBot when studying at Cleveland Institute of Art, which introduced art students to tools more commonly used by engineers. I visited Case Western to fabricate my art projects.”
think[box] serves students, alumni, and the public at large. The vast majority of users are students of mechanical engineering, computer science, biomedical engineering or aerospace engineering. Marcus said, “They use the ShopBot for project work — they all take 3D modeling classes and use SolidWorks primarily. The ShopBot is one of our most popular tools. I train folks to run this and other tools.”
Overall, noted Marcus, “the projects made here range from artistic to engineering-focused.” Here are just a small sample of the projects which make use of the ShopBot:
Portable Proximity Card Reader (a new-fangled ‘people counter’) In an effort to streamline the process of checking students in at large events, Case Western’s Student Affairs IT office has designed and made several hand-held proximity card readers compatible with Case ID’s. This completely in-house design costs less, has a greater capacity, and is significantly faster than the previously used magnetic stripe card readers. The ShopBot was used to mill a wooden mold for the thermoplastic clear cases of the counters.
Jaswig Students from Kent State milled all the pieces for prototyping this adjustable-height stand-up desk. It is now being used in homes, offices, and schools around the world.
Condado Tacos This custom exterior signage for Condado Tacos in Columbus, Ohio was made from SignFoam on the ShopBot with a v-carve bit.
Custom-built CNC router This 3-axis CNC table router was designed and built from scratch by students from the University of Akron. Fabrication occurred at think[box] where parts were cut using the ShopBot.
Mini Baja Car This vehicle competed in the Society of Automotive Engineer’s annual mini-baja competition where CWRU students designed and built the car from scratch. Although primarily fabricated in the Bingham Machine Shop, many supplemental tasks were completed in think[box]. In particular, students 3D printed mold-making patterns, cut out welding fixtures in the laser cutters, and fabricated composite floor panels for the finished car on the ShopBot.
Reading Wetu “Reading Wetu” is a project created with the first grade class of Ms. Erin Shakour at Orchard STEM School located on Cleveland’s westside during the fall 2014 semester. The reading Wetu occupies an 8′ x 8′ x 8′ area in the corner of her classroom, and houses her small library of children’s books. The structure is built entirely from 3/4″ thick plywood and yarn, and fabricated with the CNC router at think[box]. This project is part of a series of works that Marcus created in collaboration with Progressive Arts Alliance, a local arts organization whose focus is to provide STEAM (Science, Technology, Engineering, Arts, and Math) programming to the Cleveland Public School District.
I asked Marcus how students react to being introduced to the ShopBot and what it is like for them to use the tool. Marcus said, “They begin with a total fascination and awe about it, watching the tool move and cut projects. Even though CNC is an older technology it never ceases to engage interest of the new students.”
The next phase is one of “some intimidation,” noted Marcus, when students begin to understand the steps needed to get up and running. “Once they dive in and read tutorials and start using Partworks, it starts to become easier for them,” he added, “because they see that Partworks is much like software that they’re familiar with. The tool is well designed and intuitive to use, so once students get familiar with the software things become much smoother for them.”
We look forward to seeing a lot more uses for the ShopBot coming out of this amazing space!
UI1 Mobile FabLab at a Maker Faire. An awning provides extra shelter when projects are set up outside the MFL.
It’s a great idea to take the digital fabrication equipment to the people, rather than the people having to travel to the equipment. As experience and the type of equipment available have changed, the Mobile Fab Labs themselves have gone through a number of iterations. The following is a brief timeline of a few of the mobile units in which ShopBot has been a part.
MIT Mobile Fab Lab: “The Matriarch”
The original Mobile Fab Lab (2007) was designed so that the visitors would come inside to use the smaller digital fabrication equipment. A laser cutter, vinyl cutter, and minimill–as well as an electronics lab–are all accessed through the single side door.
There is a 4′ x 8′ ShopBot with a 4HP spindle fitted in the back of the trailer, with access when the tailgate is open. Nadia Peake’s video of the equipment in the original MIT Fab Lab (MFL) can be found here.
MIT campus, Fab ’11
The Fab Lab trailer is a 2007 Pace American Shadow GT Daytona dual axle (model SCX8528TA3). It is 32′ long, 8′ wide, and 7′ high. The tailgate opens to add a 6′ deck at the back of the trailer. The main entrance is a door on the passenger side towards the front. A 6.5′ tall custom steel box covers most of the tongue. The lab requires a space approximately 60′ long by 16′ wide for operation as a lab. The power requirements are 240V single phase with minimum 40A service. To run all the equipment in the lab at once (including AC and overhead lights) is about 20kW; to run only the 120V equipment is about 8kW.
The MIT MFL has made the 3,000 mile trip across the U.S. several times, and is often stationed at a location for months at a time. The trailer is pulled by a Ford F350 with a professional driver who travels to the MFL.
Experience with the original MIT MFL revealed that there could be some improvements to the design. The space inside the lab is limited. If the weather is not good (rainy, cold, too hot), then it can be difficult to use the ShopBot. The full-sized gantry ShopBot was not designed to travel long distances over bumpy roads. The power supply to the trailer can be problematic when all the equipment is running.
MC2 STEM High School Mobile Lab: 2nd Iteration
The MC2STEM Mobile FabLab (2011) was designed so that the equipment could be used in place, or rolled out of the trailer to be used in schools or for shows. All equipment is on carts, or chosen for its ability to roll and be plugged into existing outlets without requiring the services of an electrician.
The ShopBot is a 48″ wide Buddy with a Porter Cable router. At the time, the Porter Cable router was the only option to allow the ShopBot to be plugged into a standard 15A 110 outlet in the U.S. An optional 4″ power stick means that a 4′ x 4′ sheet of plywood can be machined on the Buddy.
The Buddy travels well when locked into place, can be used inside the trailer, and rolls out when necessary. The Porter Cable router (not available for international sales) is loud when used for cutting through material rather than V Carving for demonstrations.
Buddy from MC2STEM MFL rolled into position two floors up from the MFL. Shown is the standard setup, with 2′ of travel in the X (along the rails) and 4′ of travel in the Y (across the gantry). The 4′ power stick (plus out feed rollers) allows for a 4′ x 4′ sheet of material to be machined when desired.
MC2STEM High School Mobile FabLab parked next to van pulling ShopBot Cricket mobile (MIT campus, Feb. ’11). A large pickup truck is required to pull the MFL.
Inside the MC2STEM FabLab when the equipment has been rolled out for the U.S. Science and Engineering Festival
Laser cutter and other equipment outside the MC2STEM MFL. ShopBot Buddy was used in another display, so the Handibot stood in as the CNC router.
ShopBot Buddy in action, with Thinker Linker sets cut with the Buddy in the background.
- ShopBot Buddy with Porter Cable router
- 48″ wide Buddy
- 48″ power stick so can machine 4′ x 4′ material when desired
- Laser cutter (by Epilog)
- Roland vinyl cutter
- 3D printer
- Electronics lab
Chevron Mobile FabLabs: 3rd Iteration
Like the MC2STEM MFL, the Chevron Mobile FabLabs (2015) are intended to be used with the equipment inside the trailer, or rolled out when needed for a school or display. All the smaller equipment is on carts that were machined on a ShopBot (as is the cabinetry in all of the MFLs).
Carnegie Science Center Mobile FabLab onsite. Notice two doors to facilitate traffic flow through the MFL.
A generator can power the MFLs, including the ShopBot, when they are on location. The ShopBot Buddy is set up with a 1HP spindle that can be plugged into a standard 110 outlet (the same spindle is available for 220V international power).
A prototype of the carts in the Chevron MFL (designed by Nick DiGiorgio, fabricated at Lorain County Community College, Ohio).
- ShopBot Buddy with 1HP spindle
- Laser cutter (from Epilog)
- Vinyl cutter
- 3D printers
- Electronics lab
Looking towards the front of the lab.
Looking towards the rear of the lab. The ShopBot Buddy is locked into traveling mode.
- Each of these MFLs has a dedicated large pickup for towing.
- A note about power: it is best to avoid plugging the ShopBot with 1HP spindle into an outlet that has a GFI (Ground Fault Interrupt).
Tulsa Mobile FabLab
The Tulsa FabLab (2015) sets all of their equipment on sturdily built metal carts that also include storage for the materials used by the machine. The carts can be rolled into a school or demo site.
Tulsa Mobile FabLab at MIT Fab11
Tulsa Mobile FabLab getting its “skin”.
Classroom chairs machined on a Desktop
It is important to consider the width of the doorways when building a cart or ordering a machine. While the Desktop has two options of enclosures, they can be wider than the standard U.S. doorway.
ShopBot Desktop on a cart
ShopBot Desktop with 1HP Spindle (2011)
The ShopBot Desktop with 1HP spindle weighs about 115 lbs. It is an excellent solution for many applications because its 24″ x 18″ cutting area allows one to machine projects in wood, aluminum and plastics. It also has the specs to machine circuit boards. The 1HP spindle is quiet, and can be plugged into a standard 110 outlet (220 version of spindle available).
ShopBot Desktop Max with 1HP Spindle (2015)
Another Desktop option is the Max, with a cutting area of 24″ x 36″ (approximately 610mm x 914mm).
When Cricket Trailers purchased a ShopBot to fabricate their tag-along caping units, ShopBot decided it needed one to create a mobile display unit.
Originally (2012), the inside was modified from a camping unit to a two-layer bed that could hold two ShopBot Desktops. One Desktop faced inside so it could be accessed by people inside the Cricket when the roof was popped open. The second could be pulled out on to a rolling table set to the height of the back platform. A tent provides protection from the weather.
Experience showed that the inside was too small for more than one or two people. The platform was modified in 2015 to one layer, and a single Desktop rides just above the wheels for transit. The rolling table still works well. When more than one CNC machine is necessary a Handibot is added to the Cricket.
As mentioned above, it is best not to plug into a circuit with a GFI (ground fault interrupt) switch when using the Desktop with a spindle.
Desktop set up with double Z to mill and drill through circuit boards (Maker Faire New York, 2014).
ShopBot Cricket with roof popped up at a street festival. The Desktop is pulled out of the back of the trailer on to a rolling table that is the height of the back platform.
Desktop on rolling table set up under a tent.
Side door for entry into Cricket
Cricket being pulled by a 2003 Chrysler van (MIT Fab11).
The Handibot is a job-site tool, and can be transported easily on a cart or in its travel box to a job or a classroom. When packed in its shipping box or in the right suitcase, it weighs in under 50 lbs., which means it can be flown as regular baggage on just about any airline.
While small in size, the Handibot is large in capabilities. Precise enough to mill circuit boards, it easily machines wood, non-ferrous metals (such as aluminum), plastics, and machinable wax. One can also index the Handibot to machine areas larger than its 6″ x 8″ (150mm x 200mm) work area.
“My goal has always been to grow the business slowly and naturally,” reflects Dan Thomson.
Visionary Effects’ portfolio looks like a design-build team of 4 or 5 people each possessing varying skills, similar to many interdisciplinary studios. But in actuality, it is only Dan Thomson: owner, designer, fabricator, problem solver and animatronics guru.
Dan grew up in Pittsburgh obsessed with Halloween and making things in his backyard. Studying special effects for the movie industry in school, such as moldmaking and animatronics, made sense. (The department he studied in was named after horror-film legend and Pittsburgh native Tom Savini.) Upon graduating, Dan worked for a special effects company in Nashville, TN. This is where he first learned about CNC machining. A challenge presented itself: He aimed to return to Pittsburgh but, “I realized it was hard to make monsters all day for a living. There would never be enough movie industry work in Pittsburgh to make a real living. How can I take the same skill set and use it for other things,” Dan reflects, “I had to figure out how to offer my services in other avenues.”
The HearMe Kiosk’s mold was carved out of MDF and then vacuum formed in plastic.
‘HearMe’ Interactive Kiosks created for Carnegie Mellon’s CREATE Lab’s Hear Me initiative in collaboration with Laser Lab Studio, a company he often works with.
So Dan returned to Pittsburgh and increased his CNC skills. He freelanced on the side while working for a company that introduced him to 3D printing and laser cutting. A light bulb went off: He dove into learning all the software needed to run a laser cutter and other CNC machines. Dan picked up more freelance jobs, more tools, and finally felt comfortable leaving his 9-5pm job. Visionary Effects was born.
“My goal has always been to grow slowly and naturally,” Dan says. Moving out of his basement studio and into a shared studio space allowed him to take on larger jobs and to collect more tools. He needed a CNC machine to cut aluminum and other materials for animatronic pieces. “I needed something I could afford to get up and running quickly. I was looking for a used machine and got lucky that someone put up their PRS Standard 4×4 on Craigslist,” Dan says. While most begin with wood, he started cutting aluminum and other alternative materials right out of the gate. With a little trial and error mixed with a little research on the Talk ShopBot forum, he was off and running. “My industry is so variant that I don’t have the luxury of only cutting one material,” Dan explains. “One month is heavy steel fabrication with cutting and grinding and next month is doing a museum project.” He utilizes interchangeable custom dust feet with magnetic heads for cutting 1/8” aluminum versus 3” thick foam. Like most projects tackled, “I spent way too long customizing them,” Dan laughs.
Dan recreated ‘How People Make Things‘ exhibit for the Museum of Discovery in Arkansas based off of decade-old AutoCAD files. With no details in the drawings, design and assembly decisions fell to him.
“The company that originally created the traveling exhibit for the Children’s Museum in Pittsburgh went out of business. So there was no one to call to ask for help,” remarked Dan.
Over the years, Dan’s PRS 4×4 aided him not only in his design/build business. “Animatronics is such a small industry that it is difficult to find others who are doing exactly what I’m doing,” he says. The first projects he freelanced on were animatronic eye mechanisms. Drawn to this type of work during school, CGI has overshadowed this industry. “With animatronics, there’s no how-to guide and there’s only a few people in Hollywood still making these. It started out as a personal project … how to create the smallest, most real-looking eye mechanism,” Dan explains. The limitation rests on fitting the number of servos needed into the smallest space. Posting YouTube videos of his eye mechanism tests showed that others were trying, too, but they didn’t have the resources. A new business arose: He began offering his hand-painted eyes as fully assembled kits, using his ShopBot to hone the aluminum plate design. Customers expanded to China, New Zealand, Netherlands and Spain just to name a few. The eye kits plugged into whatever control system the user needed whether it was a simple radio controller or a complex computer controlled playback for a robot.
Dan hand paints all of the eyeballs used in his animatronic eye kits, which he sells to film and tv companies as well as hobbyists.
One of many challenges lies in getting all parts needed to fit into a small space.
Adjusting for limitations is part of Dan’s day-to-day work. A few years ago the University of Pittsburgh Medical Center’s marketing department contacted him about a new heart disease campaign. “The tag line was something about the chances of a piano falling on your head compared to the chances of having heart disease,” Dan remembers, “They literally wanted a piano to look as if it had fallen from the sky.” The installation needed to pack up into 2 crates, to be mobile and travel, to fit through a regular size door and to be light. All seams and hardware had to be hidden. Dan’s completed fallen piano traveled to Pittsburgh hotel lobbies, malls, and office buildings. “The clients were really pleased. And I learned a lot about pianos!” Dan laughed.
University of Pittsburgh Medical Center’s Marketing team hired Dan to create a piano that fell from the sky for a heart disease campaign.
The installation had many design limitations: Mobility, weight, and assembly just to name a few. It traveled to various locations around Pittsburgh.
Dan utilizes 1 if not 3 different CNC machines along with traditional tools on all projects. He’s let the natural progression of Visionary Effects dictate his equipment purchases. Adding additional side rails transformed his ShopBot 4×4 into a 4×8 machine. Also in his shop is a Rabbit Laser USA, a Tormach mill and most recently an Ultimaker 2. “I don’t do production. Mine is usually at most 100 of something. So my machines let me do everything I need to do,” says Dan. Project after project shows Dan’s fearless attitude towards design and fabrication challenges and faith in his skills as a maker. No doubt we will continue seeing great things coming from his interdisciplinary studio.
Follow Dan’s work on Facebook page or Instagram or Twitter
Assembled laser cut acrylic pieces for the H2O exhibit light table
Completed sign for H2O exhibit
Completed H2O exhibit light table
HDU cut on Dan’s PRS ShopBot for H2O exhibit
In mid-July, 14 people with an interest in education came to ShopBot for 2 ½ days of training. Unlike most regular trainings offered at ShopBot, we also had two other types of digital fabrication tools that are commonly found in FabLabs and MakerSpaces: an Epilog 60W minihelix laser and a Dremel 3D printer (a HUGE THANKS to both companies for lending their machines!). The overall purpose of the event was for people to experience how to use digital fabrication tools in education and cross-platform training, and allowed ShopBot to get valuable feedback from educators who are already using digital fabrication in their schools and after-school programs.
ShopBot employees entranced by the Epilog laser
Dremel 3D Printer
While everyone attending had a focus on education, the range of experience was vast: there were “newbies” who had little or no experience with digital fabrication tools, to those who had extensive experience on laser cutters or 3D printers only, to experienced ShopBot users who worked primarily in 2D machining of signs or simple projects. Two attendees were experienced FabLab “gurus”, and were able to share their expertise as well as work on projects that they never have time to do during their day to day lives. The schedule included lectures and demonstrations on a number of topics, as well as open time built in so that the attendees could work on a project of their interest with support from the extended ShopBot family.
Despite these difference, all the telltale signs of a ShopBot workshop were there: everyone introduced themselves and joined the ShopBot employees for lunch, after which founder & CEO Ted Hall told of the history and philosophy of ShopBot. Those who had limited experience with actually running a ShopBot were stepped through changing a bit and running a file before they began their own project. Sallye made a few mistakes in running a file in order to create some teaching moments.
Introductions Thursday morning
Lunch with the ShopBot employees
Open Design Time
The open time for attendees to work on their own projects extended from Thursday evening, throughout Friday, and even continued for several hours after the official end time of the class on Saturday afternoon. The one-on-one format was people-intensive, with Sallye Coyle, Chris Burns, Randy Johnson, Brian Owen and Al Nyonteh all staying late to work with individuals on their own projects. Chris Carter and Maria Melo Bento, experienced FabLab gurus, helped supervise the laser for both attendees and ShopBot employees. Jimmy Luciderme, ShopBot’s intern from France, and ShopBot’s Marketing Team adopted the 3D printer. It was chaotic but really fun.The topics for lectures included an introduction to VCarve Pro and running a ShopBot file, an explanation of design file types (2D, 3D); and how to prepare files originally intended for one machine (i.e., ShopBot) and send them to another machine (the laser). Brian Owen presented a lesson in how to download a topographic map from the Internet and create a 3D file for machining in Aspire, and David Preiss gave a presentation on Fusion 360, a parametric program offered by AutoDesk. Chris Burns gave examples of projects he uses when doing trainings in schools. Sallye included handouts in ShopBot-specific tutorials that addressed topics in Common Core and Next Generation Science Standards, as well as integrating digital fabrication projects into life skills that go beyond the actual project itself.
Newbies working together:
Bryan from a high school in Hawaii is awaiting his ShopBot, and was attending the class in order to get a jumpstart in advance of the school year. Barb is based in Baltimore, and is a member of a TIES (www.TIESTEACH.org) team that travels around the country to install full digital fabrication labs in schools (see ShopBot blog for some stories of the installs). She is very good at the administrative and organizational levels, but wanted to know more about actually using the machines that are being installed. Since both were very new to the CAD/CAM/ShopBot experience, they worked together to understand the entire process. They found the TicTacToe game created by TJ Christiansen, and downloaded the design files from the ShopBot website. To personalize the project, they scaled down the original design to fit the material available, and learned that it is really important to test the design files on screen before cutting them out on the ShopBot. Fortunately, it was relatively easy to cut another set of Xs and Os.
Maya changes a bit on the tool
Bryan following the step-by-step instructions
Tic Tac Toe created by TJ Christiansen
Bryan and Barb working together to customize the design files
Pocketing the board
Sanding, version 1: too big for board
Smaller Xs and Os, recut to fit board
Peter and Michael G came from SOCOM (Special Operations Command) in Tampa, where there is a full FabLab. As civilian contractors, they are tasked with prototyping equipment for use with the military, and with training military personnel to use the digital fabrication equipment and electronics available in the Lab. Peter has a background in 3D printing, and Michael is comfortable with a laser, but neither have logged many hours on the lab’s 4’ x 8’ ShopBot PRSalpha.
Peter decided on a rocking chair for his young daughter. While he didn’t find CAD plans online, he found pictures of one he liked, and used VCarve to trace the photographs and lay out the parts on the screen. Having decided on plywood with a nominal thickness of .5”, he used a sample board machined on the ShopBot to determine the actual size that the slots should be. Then, he copied the layout to another layer in VCarve, scaled it down so the slots were the same as the available cardboard, and cut them out on the laser cutter. The laser model showed that some of the slots were in the wrong place, so he was able to fix the design before he cut it on the Production ShopBot with Automatic Tool Changer and a vacuum holding down the table.
Sample board cut with the same bit (.25″ down spiral) and strategy (climb or conventional) that will be used for cutting the final parts. The center slot reflects the nominal thickness of the material (.5″) while the slots to either side are .02″ smaller or larger, respectively. When the sample board was tested on the actual plywood, the .46″ slot was too tight and the .48″ slot a bit too loose. So the slots in the design were set to .47″ thick.
The available cardboard measured .17″ thick, so the laser layer was scaled down to 36% of the original (0.17/0.47 = .36, or 36%).
The slot in the bottom of the chair where the key piece that holds the chair together is too far away from the back
The slot has been moved so tab fits tightly against the back of the chair
Peter with model of chair cut on the laser
Full-sized chair being cut on ShopBots production tool with ATC and vacuum hold-down
Emphasis: Inlay and pocketing: Michael G was familiar with the laser, but also wanted more experience with how to prepare models for the ShopBot. He found two types of material that were coated with a color (blue and red), and had white under them. The navy blue material was half the thickness of the red material. He created a model of the American flag with the exact dimensions that he found on the internet, experimented with toolpaths for pocketing and creating inlays, and machined an American flag.
Michael and Mike watching the Desktop machine away the red to reveal the pocket for the inlay and the white stripes of the flag
Big smiles at the finished product, with the white stars V-Carved into the blue field, and the blue field inlayed into the red/white stripes
Close-up of the flag
Simple Projects that Create Enthusiasm
Chris Burns has years of experience with ShopBot, and he brought to the training a couple of projects that demonstrate the ease of use of the VCarve CAD/CAM software and the power of the ShopBot. His example of how to create simple 2D drawings of shapes, then toolpath them to machine boxes and lids from inexpensive 2 x 4’s and 1 x 4’s caught the eye of Sarah, who is adding CNC machining to her traditional woodworking program. Not only did those who followed his tutorial get some cool boxes, but they learned important considerations in tooling, such as cutting length of the bit and how its diameter interacts with actual area machined (a rotating bit cannot get further into the corner than the radius of the bit…so one needs to change drawing accordingly).
Turning a 3D Model into 2D Build Plans: 123D Make
Sarah was also intrigued with Chris’s example of using 123D Make to turn 3D models into 2D build plans that can be machined on the ShopBot or cut on thinner material using the laser cutter. Chris brought in a boat that he had machined out of wood, then he and Sarah worked on design files to produce the same boat out of acrylic on the laser. It was Chris’ first real experience with the laser, so the event even served to teach an old ShopBotter new tricks.
Chris’ box example
Brendan from the Marketing team holding Chris’ wooden model of a boat from 123D Make
Sarah with her boat model in acrylic, cut with the Epilog laser
Creating files to be machined in 3D:
Two teachers have had 10+ years with their ShopBot, but had limited experience in doing 3D machining. Mike F from Illinois spent much of his open time learning to use Aspire to create a 3D bas relief model of an airplane he is building. A crowd gathered as the Buddy did roughing passes, then a finish pass that kept the high tips of the plane intact. Mike left thinking that it was time to upgrade his older model ShopBot to an RBK control box, and to add Aspire to his software suite.
Advanced Digital Fab users:
Maria prototyped a serving tray that took the best from both the ShopBot and the laser cutter. She used the ShopBot to pocket away material to create the rims of the tray. She then imported a photo into the VCarve software, traced photo to create the vectors, and used the ShopBot to engrave the design into the floor of the tray. She then lined up the laser cutter, and rastered the photo into the engraved area of the tray.
Finished bas relief model
Chris C. and Maria setting up for lasering a tray that had been machined on a ShopBot
Tray that has been machined on a ShopBot and enhanced with the Epilog laser
While the 3D printer did not get that much use during the event, ShopBot’s Marketing Team took the Dremel into their work area, and have been running it for a solid two weeks. The ShopBot team found the Dremel to be reliable and easy to run out-of-the-box, and it’s been in almost constant use in the two weeks since the event.
Jimmy’s part printed on the 3D printer
Mike R. runs a design shop in a theatre program. Having hands-on experience with the laser and 3D printer will help him decide if those digital fab tools are appropriate to his program, and provide ideas of how to get his students excited about using the ShopBot. John from Virginia is interested in early education, and envisions the Handibot as the tool that can encourage children in middle school and earlier to become comfortable with the concepts of digital fabrication. He came away with multiple ideas for working with his FFA students.
What did ShopBot learn?
The agenda was ambitious, perhaps overly so. Not everything got covered, in part because after lunch on Friday, only a few wanted to hear more from us. Almost everyone wanted to work on their own projects. So those who had something that they were specifically interested in got to work on their self-defined projects, while a few preferred more formalized instruction on several topics.
In order for the project-based learning to happen, there had to be a lot of tools available. On Saturday morning, all four ShopBots in the training area (three Desktops and a 32” Buddy), the PRSalpha with tool changer and vacuum hold down system in the Production Area, random Handibots, the 60W Epilog laser and the Dremel 3D printer were all in use. It also took a fair number of people to help with the one-on-one instruction.
At some points, teachers were able to share with the group what they had learned from their experience with using the tools in a classroom environment. We’ll make a list of the topics we can remember, and share them.
Should ShopBot organize another such event?
Who was invited to this event? This was our first effort at putting together an event focused on educators. It was announced in the eNewsletter, and summarized in another blog post. The sales team announced it when taking an order for a school, and an email was sent to many schools who had a relationship with ShopBot. Word of mouth is always a good way to spread the news.
If you have an interest in attending such an event, let us know. In addition to another event here in Durham, we are working with TechShop Pittsburgh to implement some of the things we learned here to a Camp there in November (see our Events Calendar). We are thinking of regional events to make it possible for others to participate without having to travel to North Carolina.
Many might be cautious of using the words ‘historic restoration’ and ‘CNC’ within the same breath. A project Charlie Robbins completed this winter proves yet again that they are modern day allies.
An Amish contractor who Charlie previously worked with requested his CNC machining expertise on a porch restoration. “The house is in an area of million dollar historical homes and it was sort of the ugly duckling,” Charlie commented. Inside contained original carvings, marble headers, marble walkways and molding, most in great condition. Charlie’s task was to recreate the porch to its original ornate form. His starting point? A few old grainy photographs and a small section of the original porch skirting. His preferred method? Aspire software and a ShopBot.
Original photograph: In-process: Final restoration
Built by a gentleman around 1890 who made his fortune in the hotel business in upstate New York, the house lost its decorative exterior over the years while keeping much of its exquisite interior. Charlie’s previous experience CNC machining outside corbels and inside molding on historic homes helped but this was the most extensive he’d undertaken.
Installing the porch skirt, which was the only real piece of the house left Charlie could use as reference.
Some of the 60 spindle turnings
Working in Aspire, he first made the basic 2D shapes of the forms, emailing digital images to the owners who were in Florida for the winter. Then he worked on the 3D modeling, sending those for approval. He took cues from the home’s interior carvings. “Everything I did the owners seemed to like. They were amazed at what the software and machine could do,” he said. Half of the 3-month project was completing the computer designs. “The customers wanted to be able to hold up the photo and see that reflection. That’s what I tried to do.” The porch skirting ended up an exact replica and the owners were thrilled with the final result.
Aspire rendering of the leaf section
Three of the leaf sections were machined in a clamshell ‘C’ with the 4th machined separately. It took about 2 hours per side using a 1/2″ ballnose for roughing pass and a 1/8″ ballnose for finishing pass with a 60 degree Vbit used for the leaf veins.
Charlie took advantage of Talk ShopBot, the ShopBot user forum. Though he doesn’t actively post or comment, he’s gained a lot of insight and tricks from reading it regularly. Charlie purchased a barely used PRS Alpha with a 12” z-axis about five years ago from someone off the forum, with an indexer that had never been set up. “I used a lot of clipart 3D carvings initially just to learn,” he says. That year a lot of friends and family received great Christmas gifts.
One of the 21 corbels
Leaf pieces and other column details
For this project, Charlie needed the indexer to be on the X-axis to machine the 11.5 foot posts. “My biggest challenge was getting the post-processor to know where the indexer was since it was not on the y-axis. I got some help from Brady Watson’s old posts on the forum and a few others.” Truing everything up to within a thousandth of an inch took half a day, which, on something that long, a mistake would be noticeable. He also worried that the motor might not handle the weight, so he again queried the forum and got a positive response. “I was really impressed with what the little motor could handle. It handled cypress and everything with no problems,” he said.
The 6 foot arches needed were done in sections, each 2 inches thick: He laminated them in layers inbetween machining.
The finished 6 foot arches
Installed 6 foot arches, corbels and 4-part leaf sections.
At his job during college, Charlie worked in a spring manufacturing plant. He was studying industrial arts education by day and spending time in his mentor’s pattern shop on the weekends. The college job ended up becoming his real job for 35+ years. Taking business classes and working his way up to become plant manager, an upper management position, he finally left. He’d had enough of the stress. Charlie always kept a woodworking shop and with his mechanical background, CNC seemed like a natural transition for him. He’d attended woodworking shows and new the ShopBot name. Since that time, he’s completed Rhino classes, attended McGrew’s Aspire Camp and plans on attending the Vectric User Group in October.
The 11.5 ft. posts were turned using a 5/8″ ballnose for roughing then 1/2″ ballnose for finishing. Machining times ran about 5 hours per post with very little sandy needed.
“My interest lies in the critical thinking of how can I do this or that on my machine,” he says. The 4-part leaf section is a perfect example of this: All pieces were designed so the contractor could assemble them on location (see leaf machining photo above and caption for details). Now with a horse farm way out in the countryside, he does commissions and other “weird projects” that he picks and chooses. “Technology is so amazing that I wish I had more time to play with it. I love taking classes and learning more. I’m just excited about what is available now,” he reflects. “There’s always been value in making something.” Charlie plans to do more restoration work using the ShopBot to overlap the boundaries of historical work and digital fabrication.
With his ShopBot and indexer he says, “There’s nothing I haven’t been able to do that I’ve tried to make with the machines. The traditional tools now support them.”
Split turned newel post: Charlie glued them up with paper in the center, which allows for easy separation on the center of the turning. Half the post was mounted on the wall with the hand rail attached to it.
The original top medallion was found underneath some siding but still had to be replaced.
Installing the railing
Detail of porch
Finished install: Now for the final painting.
Feel free to contact Charlie for your CNC needs.
Autodesk Forge DevCon 2016
Last October at the NY Maker Faire, 100kGarages collaborated with Josh Worley of Opendesk on an event we named MakeLocal. It took all the steps that go into shopping for a product and having it fabricated locally, specifically for you, and compressed that big-picture concept of local digital manufacturing into a 10’x20′ space. It really got a lot of attention and helped Maker Faire attendees understand what the “New Industrial Revolution” is about, so when our friends from the Autodesk Fusion 360 and Forge teams asked us if we would be interested in participating in their Forge Developer conference at Fort Mason in San Francisco, we realized we had a great partner for another round of the MakeLocal experience.
The sort of fabrication-on-demand that we had done in New York is a big part of the distributed manufacturing story, but another important facet is customizing products so that they are uniquely suited for an individual customer. Since in New York we had taken local manufacturing story through all of the steps from design to product, we decided that at the Forge event we would instead pick one design and work with the Autodesk team to create a customizing interface from within Fusion 360. One of our favorite pieces was the Johann stool, designed in France by designer Johann Aussage of Nouvelle Fabrique, so we decided that it would be the perfect product to use for the Forge event.
Since personalization and customization was the story we were telling this time and not the fabrication of the stools, I pre-cut the stools parts into a stack of 24″ x 30″ x 5/8″ Baltic Birch blanks in my shop, leaving the pieces still held in the sheet with tabs. The 24″ x 36′ cutting area of the Desktop MAX was the perfect size to machine the designs that attendees would create for the seats of their stools. And just like in New York, one of the Shelter 2.0 designs was assembled as a stand-in for a full fabrication shop.
To help pull all the pieces together we had two great partners at Autodesk, Patrick Rainsberry and Brian Ekins. Patrick is a Business Development Manager at Autodesk, working on developing partnerships for the Fusion and Forge platforms, and is passionate about the power of software to make real things. You can see some of Patrick’s projects on his YouTube channel. including this very cool start-to-finish parametric bookcase created in Fusion 360 and fabricated on a ShopBot.
Brian is an API Designer for Autodesk, one of the authors of the Mod the Machine blog, and luckily for us an avid woodworker. Brian created an add-in for Fusion, written in the programming language Python, that created the user interface for customizing the design and creating Sketch data. These scripts also created gcode toolpaths from that Sketch geometry and send those toolpaths directly to the job queue on the Desktop MAX using the new Fabmo API.
We could only do a limited number of the customized stools because of the time the process took, so we duplicated the same process with 2 Handibots in an engraving station. Attendees used the exact same customizations in 3″x4″ badge blanks cut from 1/16″ engraving plastic. A custom vacuum holding jig was created for each Handibot station, using brake bleeder pumps as a simple vacuum source.
Although this was a developer conference with talks on topics like “Building Data Centric Applications on Forge” and “Integration and Extension of a Cloud Security Model within Enterprise systems”, Josh and I were invited to speak on a topic that we are both pretty passionate about, “The Power of Communities for Design and Manufacturing”. It was a great opportunity for us to talk about our experiences with 100kGarages and Opendesk, our thoughts on the future of manufacturing, some of the struggles that we’ve encountered, and how we see the Forge Platform and the developer community becoming a critical part of solving these problems.
Autodesk Forge DevCon 2016
We’re really not sure where our work with Fusion and Forge will lead, but are looking forward to more projects with them in the future.