WORK SURFACE I highly recommend getting an Olfa knife. It is difficult to cut 1/2 foamcore with just an Exacto. RAZOR KNIFE CUTTING MAT WIRE CUTTERS

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Ernest Jacobs
5 years ago
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RAZOR KNIFE CUTTING MAT WIRE CUTTERS MARKING TOOLS PLIERS

16 RULER HOT GLUE GUN RIGHT TRIANGLE SCREWDRIVER Find a

Ideally you ll be working with 4 x 3 sheets, so a

A large piece of cardboard will do, but I would highly

prefer, a pencil and eraser will work as well.

and 1-1/8. A compass will work just as well.

A 24 C-Thru ruler will make your life much easier.

These instructions are designed to take advantage of the

These will be important for cutting thin steel cable and

A needle-nose or any other variety will work well.

1 RAZOR KNIFE CUTTING MAT WIRE CUTTERS MARKING TOOLS PLIERS CIRCLE STENCIL SMALL WOOD SAW COMPASS 12 METAL RULER* > 16 RULER HOT GLUE GUN RIGHT TRIANGLE SCREWDRIVER Find a sturdy table that is in a well-lit area. Ideally you ll be working with 4 x 3 sheets, so a suitably sized surface will help. A large piece of cardboard will do, but I would highly recommend a cutting mat. Mine is 18 x24 and made by Artool. I use an ultra fine point black Sharpie, but if you d prefer, a pencil and eraser will work as well. The two hole diameters which you ll need to mark are 5/8 and 1-1/8. A compass will work just as well. A substitute for the circle stencil. Highly recommended. A 24 C-Thru ruler will make your life much easier. Make sure that it has 1/16 markings throughout. These instructions are designed to take advantage of the factory-square edges of the foamcore. This tool is optional. ILAN E. MOYER SHEET 1/15 WORK SURFACE I highly recommend getting an Olfa knife. It is difficult to cut 1/2 foamcore with just an Exacto. These will be important for cutting thin steel cable and stripping the stepper motor wires. A needle-nose or any other variety will work well. If you want to save money and use wooden dowels, you ll need this to cut them to length. A real saw works even better. I cut everything freehand, but if you re bad at cutting straight lines or want to better protect your fingers, grab one of these. Mine is made by Surebonder and has both a high and low temperature setting. I run it at high. You ll need a medium sized flat head screwdriver. 066 FOAMCORE CNC: VISUAL TOOL GLOSSARY 3/17/2011

ALUMINUM SHAFTS WIRE ROPE QTY: 3 QTY: 25 FT These shafts are made to be very straight with highly accurate diameters.

00 EA, $27.00 TOTAL P/N 1031K14 $0.41/FT, $10.25 TOTAL P/N 8930T22 DOUBLE-STICK TAPE QTY: 2 PACKS QTY: 1 ROLL $3.

Double-stick tape is used to laminate the delrin strips to the foamcore, as well as generally to stick things

93 TOTAL P/N 76405A13 CONSTANT-FORCE SPRING ELECTRICAL TAPE* QTY: 1 Local Hardware Store This tape-measure-like

load on the Z-axis stepper motor. $5.17 EA, $5.

foamcore in places where it might dent or wear. QTY: 20 FT $0.39 /FT, $7.

alternative to steel dowel pins. Purchase at least 18 of both 1/4 and 1/2 diameter wooden dowel. ~$3.

This flexible and somwhat stretchy tape will be used to couple the motors to the aluminum shafts, as well as to

POLYESTER TAPE I really like this plastic-backed adhesive tape, but you could get by with masking tape or clear tape.

You ll need a 4 x 3 sheet of 1/2 thick foamcore, and a 3 x 2 sheet of 1/4 thick foamcore.

00 Local Art Store STUBBY STEEL DOWEL PINS* ALUMINUM SPACER QTY: 2 PACKS (20) QTY: 3 These pins will get the job

If you can t use wooden dowels, you ll need to find or create cylinders which are 1/2 dia. and long.

This fine braided steel cable will prevent the aluminum shafts from spinning without also rolling.

They provide a low-friction bearing for the moving parts of the machine. 1/2 inner diameter. OR SHEET 2/15 $6.

30 TOTAL P/N 98381A710 These spacers coincidentally have the right inner and outer diameters to adapt the 5mm motor

SLENDER STEEL DOWEL PINS* SUPERGLUE* QTY: 1 PACK Local Hardware Store These pins will get the job If you can t use

2 ALUMINUM SHAFTS WIRE ROPE QTY: 3 QTY: 25 FT These shafts are made to be very straight with highly accurate diameters. They are responsible for both moving and guiding the toolhead and the Z axis table. 1/2 diameter x 15 long. $9.00 EA, $27.00 TOTAL P/N 1031K14 $0.41/FT, $10.25 TOTAL P/N 8930T22 DOUBLE-STICK TAPE QTY: 2 PACKS QTY: 1 ROLL $3.15 /PK, $6.30 TOTAL P/N 6389K623 An adhesive-paper-adhesive sandwich. Double-stick tape is used to laminate the delrin strips to the foamcore, as well as generally to stick things together. $7.93 /ROLL, $7.93 TOTAL P/N 76405A13 CONSTANT-FORCE SPRING ELECTRICAL TAPE* QTY: 1 Local Hardware Store This tape-measure-like spring unravels with consistent force, making it ideal to counter the weight of the Z -axis table and to reduce the load on the Z-axis stepper motor. $5.17 EA, $5.17 TOTAL P/N 9293K44 DELRIN STRIP Thin strips of delrin, an engineering-grade plastic, are used to to reinforce the foamcore in places where it might dent or wear. QTY: 20 FT $0.39 /FT, $7.80 TOTAL P/N 2638T11 WOODEN DOWELS If you have the ability to cut them, wooden dowels are a cheap and effective alternative to steel dowel pins. Purchase at least 18 of both 1/4 and 1/2 diameter wooden dowel. ~$3.00 TOTAL Local Art Supply Store Any color will do. This flexible and somwhat stretchy tape will be used to couple the motors to the aluminum shafts, as well as to insulate wiring connections. POLYESTER TAPE I really like this plastic-backed adhesive tape, but you could get by with masking tape or clear tape. It is used as a general tape wherever necessary. QTY: 1 ROLL $6.81 /ROLL, $6.81 TOTAL P/N 7630A42 FOAMCORE! You ll need a 4 x 3 sheet of 1/2 thick foamcore, and a 3 x 2 sheet of 1/4 thick foamcore. Several smaller sheets can be used instead of a big sheet - check the cut patterns. ~$13.00 Local Art Store STUBBY STEEL DOWEL PINS* ALUMINUM SPACER QTY: 2 PACKS (20) QTY: 3 These pins will get the job done, but are expensive so search for alternatives first. If you can t use wooden dowels, you ll need to find or create cylinders which are 1/2 dia. and long. + The motion system of the machine relies on what is called the capstan effect. This fine braided steel cable will prevent the aluminum shafts from spinning without also rolling. NYLON BUSHINGS Molded plastic sleeves which are designed to slide on precision shafts. They provide a low-friction bearing for the moving parts of the machine. 1/2 inner diameter. OR SHEET 2/15 $6.65/PK, $13.30 TOTAL P/N 98381A710 These spacers coincidentally have the right inner and outer diameters to adapt the 5mm motor shaft to the 1/2 aluminum shafts. SLENDER STEEL DOWEL PINS* SUPERGLUE* QTY: 1 PACK Local Hardware Store These pins will get the job done, but are expensive so search for alternatives first. If you can t use wooden dowels, you ll need to find or create cylinders which are 1/4 dia. and 2 long. $8.85/PK, $8.85 TOTAL P/N 90145A549 $1.54 EA, $4.62 TOTAL P/N 92510A745 Any super glue will do, although the thinner the better. I use this awesome 5cP glue, but 100cP would be OK too. (cp is a measure of fluid viscocity.) HOSE CLAMPS Typically used to secure hoses to fittings, we will use hose clamps as simple tensioning mechanisms for the steel cables. QTY: 1 PK TOTAL MATERIAL COST: $ $7.01/PK, $7.01 TOTAL P/N 5388K22 STEPPER MOTORS These easily controlled motors will move the toolhead around with some degree of precision. The type depends on your controller, but I will be using unipolar motors with a step angle of 0.9. QTY: 3 Alltronics ILAN E. MOYER $6.95 EA, $20.85 TOTAL P/N 28M053 * These are either household items or alternative parts and are not included in the calculated parts price. 066 FOAMCORE CNC: VISUAL BILL OF MATERIALS (BOM) 3/17/2011

3 Your Order 3/20/11 7:39 PM Date Purchase order Order created by March 20, 2011 Ilan Moyer Ship to 3 Ames Street East Campus, #358 Cambridge, MA Send invoice to imoyer@mit.edu Payment method Attention: Ilan Moyer Shipping method Ground Line Quantity Item Ships Unit price Total 1 3 each 1031K14 Precision Ceramic-Coated Aluminum Shaft 1/2" Diameter, 15" Length 2 2 packs 6389K623 Nylon Bearing Flanged, for 1/2" Shaft Dia, 5/8" OD, 1/2" Length, packs of each 9293K44 Stainless Steel Constant-Force Spring 4000 Cycle Life,.005" Thick, 17" L,.312" Wide Monday morning $9.00 each Monday morning $3.15 pack 6.30 Monday morning $5.17 each ft. 2638T11 Black Delrin Strip.020" Thick, 1" Width Monday morning $.39 ft packs 98381A710 Alloy Steel Dowel Pin 1/2" Diameter, 3/4" Length, packs of pack 5388K22 Worm-Drive Hose Clamp W/Zinc Pltd Steel Screw 11/16" to 1-1/4" Clamp Dia Range, 5/16" Band Width, packs of ft. 8930T22 Commercial Grade Nylon-Coated SS Wire Rope 7X7 Strand Core,.018" -.024", 40# Break Strg 8 1 roll 76405A13 Masking Tape - Adhesive on Both Sides for General Purpose, 1" Wide X 36 Yards Long 9 1 roll 7630A42 High-Temp Polyester Masking Tape 1" Wide X 18 Yards Long 10 3 each 92510A745 Aluminum Unthreaded Round Spacer 1/2" OD, 1/2" Length, #10 Screw Size 11 1 pack 90145A Stainless Steel Dowel Pin 1/4" Diameter, 2" Length, packs of 10 Monday morning $6.65 pack Monday morning $7.01 pack 7.01 Monday morning $.41 ft Monday morning $7.93 roll 7.93 Monday morning $6.81 roll 6.81 Monday morning $1.54 each 4.62 Monday morning $8.85 pack 8.85 Merchandise total $ Applicable shipping charges and tax will be added. Phone (609) Fax (609) Internet nj.sales@mcmaster.com Page 1 of 1

4 MATERIAL: FOAMCORE SHEET 3/ /4 2 1 / /4 NOTE: SAVE THIS INTERIOR PIECE BECAUSE IT BECOMES THE MACHINE S WORK TABLE / SKETCH LINE CUT LINE ILAN E. MOYER 066 FOAMCORE CNC: AND TABLE CUT PATTERN 3/12/2011

5 MATERIAL: FOAMCORE SHEET 4/ / / / / /8 3 /8 3 /16 3 /4 1 1 /8 1 3 / / SKETCH LINE CUT LINE ILAN E. MOYER 066 FOAMCORE CNC: CUT PATTERN 3/12/2011

6 MATERIAL: 1/2 FOAMCORE SHEET 5/ SKETCH LINE CUT LINE ILAN E. MOYER 066 FOAMCORE CNC: BOTTOM PLATE CUT PATTERN 3/12/2011

7 MATERIAL: 3 /16 FOAMCORE 3 /16 WIDE LEG 13 SHEET 6/15 3 /8 5 / /16 3 /16 NARROW LEG /8 3 /8 QTY /8 TILING PATTERN 7 11 / SKETCH LINE CUT LINE ILAN E. MOYER 066 FOAMCORE CNC: LEGS CUT PATTERN 3/12/2011

8 SHEET 7/15 1 S QTY 4 3 S QTY 6 LARGE STRIPS SMALL STRIPS STRIPS /4 11 SPLIT FULL SPLIT FULL TOTAL SPLIT LENGTH: 73.5 TOTAL FULL LENGTH: 125 OVERALL LENGTH: Total split length is the total length of wide delrin strip which needs to be halved along its length. Total full length is the total length of delrin strip which will retain its original width of. SPLIT FULL QTY 8 SCORE LINE CUT LINE ILAN E. MOYER 066 FOAMCORE CNC: DELRIN STRIPS CUT PATTERN 3/18/2011

9 SHEET 8/15 LARGE STRIP - SPLIT FRONT OF MACHINE LARGE STRIP - FULL SMALL STRIP - SPLIT BACK OF MACHINE LARGE STRIP - SPLIT NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16. ILAN E. MOYER 066 FOAMCORE CNC: DELRIN STRIP PLACEMENT - OUTSIDE SURFACE 3/19/2011

10 SHEET 9/15 3 /16 3 /16 SMALL STRIP - FULL FRONT OF MACHINE 3 /16 SMALL STRIP - SPLIT SMALL STRIP - SPLIT BACK OF MACHINE SMALL STRIP - FULL NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16. ILAN E. MOYER 066 FOAMCORE CNC: DELRIN STRIP PLACEMENT - INSIDE SURFACE 3/19/2011

11 SHEET 10/15 TOP OF MACHINE STRIP - SPLIT STRIP - FULL STRIP - FULL STRIP - SPLIT BOTTOM OF MACHINE NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16. ILAN E. MOYER 066 FOAMCORE CNC: DELRIN STRIP PLACEMENT - INSIDE SURFACE 3/19/2011

12 SHEET 11/15 TOP OF MACHINE STRIP - FULL STRIP - FULL STRIP - FULL STRIP - FULL STRIP - FULL STRIP - FULL BOTTOM OF MACHINE ILAN E. MOYER 066 FOAMCORE CNC: DELRIN STRIP PLACEMENT - OUTSIDE SURFACE 3/19/2011

13 WIDE LEG NARROW LEG NARROW LEG SHEET 12/15 WIDE LEG FRONT OF MACHINE FRONT OF MACHINE TOP VIEW BACK OF MACHINE BACK OF MACHINE NARROW LEG NARROW LEG ILAN E. MOYER 066 FOAMCORE CNC: STRUCTURAL ASSEMBLY GUIDE 3/19/2011

14 MATERIAL: 3 /16 FOAMCORE SHEET 13/ /4 2 3 /4 1 / /8 4 5 SKETCH LINE CUT LINE ILAN E. MOYER 066 FOAMCORE CNC: TABLE STRUT CUT PATTERN 3/12/2011

15 MADE FROM DELRIN STRIP MADE FROM 3/16 FOAMCORE SHEET 14/15 QTY 3 QTY 4 3 LAMINATED WITH ADHESIVE 1 1 /4 3 /16 QTY 1 2 UNLAMINATED 3 / /4 CUT LINE ILAN E. MOYER 066 FOAMCORE CNC: Counter Spring and Table Miscellaneous Pieces 3/20/2011

16 SHEET 15/ /16 3 / / / / /16 NOTE: IF POSSIBLE USE A FACTORY-CUT EDGE OF THE FOAMCORE SHEET FOR THIS SURFACE. 4 MATERIAL: 3/16 FOAMCORE QTY 3 3 /4 4 SIDE PLATE MATERIAL: 1/2 FOAMCORE QTY 6 BEARING STRIPS MATERIAL: DELRIN STRIP, LAMINATED WITH ADHESIVE QTY 12 SKETCH LINE CUT LINE ILAN E. MOYER 066 FOAMCORE CNC: STEPPER MOTOR MOUNTS 3/20/2011

Gear Drive Hapkit Assembly Instructions

Gear Drive Hapkit Assembly Instructions (1) Order and Print the necessary parts Figure 1: 3D Printed Parts and Hardware Note: The screws shown were replaced with button head screws and the second pair