My first full 360 carving!

[adprinter]

I just finished my very first full-360 degree 3D carving. It is a fantasy sword that my daughter drew (my little Master Artist!). Carved from laminated Oak, and measures 26" long. The artwork was drawn in Corel Draw, and the tool path was created using MeshCAM Art. Cut time was 11 hours per side (22 hours total). The photo is just after finishing the cut out on the second side. Not yet sanded, or finished. Will eventually be used as a pattern for a sand mold to be cast in Aluminum.
-Michael

[DonFrambach]

Very nice! How did you register the piece so that it was cut properly when you flipped it over?

[adprinter]

Originally Posted by DonFrambach Very nice! How did you register the piece so that it was cut properly when you flipped in over?

I drilled a thru hole at X0Y0, and X26Y0- then flipped the piece, and inserted a foam rubber pad under the stock (to provide support for the piece already cut), then loaded the mirror image file, and painstakingly jogged the machine into alignment with the thru holes, and re-zeroed X and Y.
This involved Slowly jogging the cutter into the holes, and rotating the router by hand to insure the cutter was centered in each of the two holes. Had to bump the piece around by tapping with a hammer with clamps loosely tightened until I got it just right. This was actually the SECOND attempt at doing this. On the first attempt, I was so obsessed with the registration process, that I FORGOT to load the mirror image file! Obviously, that didn't work out too well... so it was start over! This one turned out great!

[DonFrambach]

Originally Posted by adprinter This one turned out great!

Sure did! I hope you post a picture of the final product.

[Shargo]

A tip for the next time:
If you can accept two guiding holes make them through the whole piece as the very first operation and into a supporting block under. Then install a couple of guiding pins in the support block, remount the block to be machined and run side one.
Then all you have to do is lift the piece from the support block, flip it over and put it back on the pins!

[adprinter]

Originally Posted by adprinter I drilled a thru hole at X0Y0, and X26Y0- then flipped the piece, and inserted a foam rubber pad under the stock (to provide support for the piece already cut), then loaded the mirror image file, and painstakingly jogged the machine into alignment with the thru holes, and re-zeroed X and Y...

This was an inaccurate statement (I did NOT Re-Zero X and Y in Mach3)- the rest of the process is what I did to "Find" zero on the X and Y. To Shargo, Thanks for the tip. I actually considered doing just that. But the problem was the stock size I was working with, did not leave enough room outside the carving area to accommodate registration holes. Obviously pins could not be used inside the area to be carved, as this would have resulted in damaged cutters. I am working on a jig plate, to be permanently bolted to the table, with two pins for registration which will be located outside of the carving area. All future stock pieces would then be drilled outside the area to be carved, and mated to the pins. I agree that it would make things a LOT easier. Simply remove the stock after the first side is cut, place the foam support on the table, flip the stock and seat it onto the registration pins, load the mirror image file, and click cycle start!