CAD CAM tutorial

CAD CAM tutorial
by D.  Scott Williamson

This tutorial will show you how to use Computer Aided Design and Computer Aided Manufacturing or CAD CAM tools to create and preview a Gcode file of the Workshop 88 logo that can be run in a 3 axis CNC Mill.

Background

There are 5 main types of machine operations

  1. Engrave (follow path): The tool tip will follow the 3D path provided.
  2. Profile: The tool edge will follow either the inside or outside contour of a path down to the specified depth.
  3. Pocket: The tool will remove all the material within a contour down to the specified depth.
  4. Drill: A drill routine will be executed at each point location.  Drill routines come in 2 flavors:
    1. “Peck” used with drill bits, drills to successively deeper depths liftig the bit out of the work regularly to clear chips from the flutes.
    2. “Spiral” used with endmills that are a smaller diameter than the finished hole.
  5. 3D relief: The tool tip will remove material above a 3D surface usually specified in a 3D model or a 2D height map image.  There are two main modes:
    1. “Waterline” similar to inverted pocket operations where bulk material is efficiently removed outside the 3D model to a number of stepped depths resembling waterline in a topological map.  Typically used in a first pass with a large roughing bit to remove the bulk of the material.
    2. “Raster” moves the tip of the bit smoothly over the model in a raster pattern.

Gcode is a “numerically controlled programming language” which is why a Gcode file extension is typically .nc.  It is a human and machine readable text file.  You will rarely if ever need to look at or edit the Gcode.

Overview

This tutorial will demonstrate Engrave, Profile, and Pocket operations, which are the most popular.

There are 4 steps to this tutorial:

  1. Create a .svg file containing paths needed for machine operations
  2. Create machine operations
  3. Export Gcode
  4. Simulate, visualize and validate

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THOTCON 0x5 Badge Revealed

Link

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THOTCON  is the annual, small venue, hacking conference based in Chicago IL, USA. THOTCON is a non-profit, non-commercial event looking to provide the best conference possible on a very limited budget.

For the past 2 years Workshop 88 has been honored to design and produce the electronic attendee badges for the conference as a service to the local community.  The badge crew this year consisted of: Paul Reich, Bill Paulson, Karl Knutson, Zach Cassity, Russell Lankenau, and Rudy Ristich

This year’s badge was inspired by portable gaming systems from the past and featured  102 x 64 pixel graphic LCD screen and a push button interface. Once again, the badge features an Atmel AVR based microcontroller. The badge used nearly every byte of the 32k available SRAM on its Atmega32u4 chip.  The software consisted of a Break-out style game which participants could play to passtime, a complete schedule of talks and labs for the day long conference,  and the ability to patch into arcade panels hosted in the Hacker Village, and a few surprises for discovering inside.

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Just like the THOTCON 0x4 Badge, the 0x5 Badge is compatible with the Arduino open hardware programming environment and can accept standard Arduino shields. This means the badge can be easily reused and repurposed to power any sort of project. An improvement from last year’s badge is that no additional parts need to be added; conference goers can simply plug the badge into their laptop once burning a bootloader to reprogram it, encouraging easier exploration and badge hacking.

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The badge is designed to be completely open hardware and software.  Workshop 88 would like to thank the open source hardware and software community especially: Arduino, Oliver Kraus and other contributors to the U8glib graphics library, Dean Camera for the LUFA Project, and last, but far from least: Twisted Traces, our local assembly partner in Elk Grove, IL.

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Workshop 88 will be holding a badge hacking contest throughout the month of May.  Judging will consist of a panel from Workshop 88 and the THOTCON crew.  Interested contestants can register on the badge website: http://badge.workshop88.com

Full details on the badge specifications and firmware will be released on May 1st in conjunction with the opening of the badge hacking contest.

Lots of lasers!

Originals0701Mark Edmonson recently donated a big box of pretty high quality used battery powered laser levels to us.  They’re in various states, from apparently completely functional to rather dead.

Each one contains 5 diode lasers, as well as some other parts.  There are fairly complete teardown notes and pictures here.

Parts0769Here are the parts I salvaged from one.

Thanks, Mark!

Massimo’s great talk

MassimoRachelJimTwo members of Workshop 88 went to hear Massimo Banzi’s talk on Arduino, open source hardware and more.  The talk was part of Ge Garage’s Idea Week.  He gave some great stories of the philosophy, joys and problems of putting the Arduino out as open source hardware.

Among many other insights, he described how the fashion industry – with no intellectual property protection – made a lot more money than the entertainment and music industries with all their DRM efforts.  He told of the value of the many iterations of Arduino and how a primary metric of its success was the time between a new user opening the box and getting a useful result.  We learned it was named for a bar where they held many design meetings.  It was a great talk.

SignedArduino0243-300Rachel also scored some excellent networking time with Massimo, including connections that will be very useful in her upcoming trip to the Rome Maker Faire.  Jim brought home a newly autographed Arduino that had run the dollhouse at Rachel’s New York Maker Faire booth.

(Thanks to Drew Fustini from PS:1 for the lead picture!)

 

 

THOTCON Badge Hacking Contest Begins!

We’ve all had a full week to recover from the THOTCON and B-sides activity here in Chicago and it is time to get back to hacking.    The badge that was distributed to THOTCON attendees was designed to be hacked and reused in your projects. In the spirit of badge hacking we’d like to announce our first badge hacking contest for the attendees of THOTCON 0x4.

The contest will start today and will run until 11:59 pm CT on Monday, May 27th 2013.

The rules are simple: In hacking there are no rules.

Although there are no rules your submission must be reproducible and should include:

  1. Video Demonstration of your Badge Hack
  2. Any applicable schematics for your hack
  3. Any code and compile instructions

In the interest of collaborative learning any requested information about the badge for the purpose of the contest will be shared with other contest participants. All contest submissions will also be archived on the official badge website.

There will be several categories we will judge against, you’re automatically entered to each category:

  • Best overall badge hack (make us say uhh!)
  • Most hackerish hack (what can you hack with the badge?)
  • Most unorthodox hack (does your badge now dispense cat food?)
  • People’s choice (the tubez chuze)

The prizes will be notoriety and some 3D printed randomness courtesy of the badge crew at Workshop 88.

The astute observer will notice that the pin outs on the side of the board fit the Arduino footprint for access to many of the ATMEGA128RFA1’s peripheral systems and compatibility with most Arduino shields.  The badge can be easily reprogrammed  via the unpopulated ICSP header with (at least) the following methods:

If you’re looking to hack your badge over and over again we have a few left over prototyping kits we were selling during the con and you can get them for $20 plus shipping by emailing us here. 

These include all the prototype rails and headers you need to use arduino shields  plus the passive components necessary to power the badge from a wall wart or other external supply.  The power system components are not necessary to reprogram or hack the chip.

Register here for the contest!