Re: [CAD_CAM_EDM_DRO] 5-Axis help

No offence, Isaiah, but I did have a good chuckle when I got to the last
couple of lines of your post! Don't worry, as the others have suggested
we can definitely help you out, but you will reap huge rewards for your
final successful outcome if you invest a tiny bit more time in research...

Read the FAQ's at

http://www.ktmarketing.com/faq.html

and follow the links that are posted as you need to familiarise yourself
with more machine designs and driver designs. Also, you need to
consider walking before you run. As you evolve your machine design,
consider designing for three axis but leave provision for additional
degrees of freedom in a subsequent upgrade of your machine. Many here
have started with three axes and and added a 4th as budget and
experience permit. It isn't just having a 5 axis machine at your
disposal, it is knowing how to use it without crashing it... Also, many
complex parts are now being made (prototyped) with solid lithographic
printing technologies. Realistically, a 5th axis is rarely required for
most designs - you can always make your design in sections and assemble
etc.

Your intended work envelope is very ambitious for a first timer. You
will save time and money if you start smaller - remember you can always
scale your designs later. Also, what do you intend to machine? Wood?
Foam? Stainless steel? Huge differences in machine stiffness
requirements. What tolerances do you want to maintain? .001"? .010"?
How fast do you want the tool head to move? Faster = more $$$ Lots of
things to consider!

If you are studying ID you likely have access to a solid modelling
package? What is it? Also, you will learn that good design includes
such things as "design for manufacture" which means that while anything
can be made, taking into account good DFM practices, it can probably be
made (and serviced and repaired) easier, cheaper with minimal loss of
appearence or features. i.e. you could design for the part to be made
on a 3 axis mill - in sections. The final design would probably be
injection moulded anyway and that introduces a whole bunch of additional
design abnd manufacture issues. You also will learn about ergononomics
etc. Making things look cool and be easy to use is always an exciting
challenge. Wait till you put your design in the hands of users and see
how they mis-use and abuse your intended design. It will blow your mind
- but remember, users will also give you the best feedback about what
they like and don't like and your design will be better for the input.

One thing that will reap huge benefits to you is in building your own
CNC mill, and then trying to make stuff, you will learn about all of the
practical challenges and compromises that exist when the "tool hits the
metal"... The reason that 5 axis machines are relatively rare is that
not only is the machine more complex, but the CAM software that
translates the solid model into 5 axis movement is always machine
specific and VERY expensive as there are so many variables to take into
account.

Read, read, read and ask lots of questions. Good luck.

Cheers, Peter



isaiah_bellais wrote:

>Hello all. I am interested in building a 5 axis router mill like the
>one here: http://www.ctek-on-line.com/5axisgm2.html. Of course the
>one I have in mind is much smaller.
>A little back ground; I am a beginner industrial designer and know
>that some of the big companies have their prototypes built in these
>big machines. Most of the work that I do can easily be done on a
>smaller 5-axis gantry mill. I would like to mill something in a 2'-
>3' cube area. Has anyone attempted to build anything like this? Is
>it feasible? I'm a bit lucky that I can get an aluminum frame built
>for next to nothing but my main problem is the drivers to run the
>stepper motors. The 5-axis drivers are considerably more expensive
>than their 3-axis siblings. Why? I have no knowledge of electronics
>so I can't design a driver myself. I've noticed tons of home built 3-
>axis drivers on the web but can't seem to find any 5-axis drivers.
>Has anyone on this discussion board built a driver for this type of
>application? If so, are you willing to help a struggling student? :)
>Am I in over my head? Although I'm not very knowledgeable with
>electronics, I am very technical and don't get discouraged easily. I
>have been researching this for about two weeks now and am hung on
>this one problem. Please help!
>
>Cheers!
>Isaiah Bellais
>
>
>
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