5 axis CNC machine?

[jkyle69]

I am looking to make a 5 axis CNC machine (I know it will take a while) - it is to machine foam to make car designs. As you can imagine it would have to be large so I was wondering if this is possible and if there are any designs to use to make this type of machine (high density foam - 4m long 1m high 2m wide). A DIY machine will still be a LOT more economical than buying a machine I should imagine. Advice appreciated as I am new to this.

Thanks

John

[cadman]

There have been a few forums here concerning DIY 5 axis machines. Do a search and read through them. The short answer is no; when you start talking about building 5 axis routers it is not more economical to build one versus buying one. Small DIY 5 axis machines that actually work are around but they have rather limited usefulness. The majority of them are not rigid, very fast or very accurate and still cost a good chunk of change to make. Then there is the issue of cad cam. Go read those forums.

Good luck
CM

[Dan B]

To purchase a 5-axis machine capable of handling the work envelope you require is going to be very expensive. You would need a gantry style machine like a Breton, for example. There is a local company that bought a machine similar to that, but not as big, and they spend $1.5 million.

As for programming, you need to determine if you need simultaneous motion, or if 3+2 positional programming would suffice. Full simultaneous capability will require more expensive software, but 3+2 can be done in lower priced software, like Visual Mill. I guess, if you spend over a million bucks for a machine, spending another $75K for Tebis, isn't that big a deal.

Dan

[txcowdog]

Check this site for free plans to make a router of the size you need. This guy built a car from scratch. Not a model of a car, but, a full size car. The working size of the machine is 9' x 9' x 4' .Yes that is feet , not inches. He said it only cost $1500 to build. And now the link is http://www.grabercars.com/content/view/67/2/

[damn_wooki]

I share similar interests to you. I know 5-axis sure is sexy, but is it an absolute necessity? As others have pointed out, the big time cost is the software to program the beast. I see you've already found the CadCut router plans. His site shows him cutting foam boats. You could then come back over it with the "elbow axis".

Something like that coupled with this:
Millit
for those undercut/interior parts might be the way to go.

[Dan B]

Programming simultaneous motion does require a little more effort than 3+2 (positional indexing)

Now you need to be aware of not just where the tool tip and shank are, but where is the holder, the head of the machine, the part in relationship to the moving parts of the machine etc. It's not rocket science, but it is something to think about if that is the direction you want to go. Personally, I feel that 3+2 can handle almost any scenario (with the exception of impellers and turbine blades). For 3+2 there are a lot of cheaper options (RhinoCam is a good example)

Just my 2 cents,

Dan

[jkyle69]

Has anyone have any plans for making a 3+2 mill? I had thought of the possibility of using a 3 axis design and then adding an elbow attachment with a 270 degree arc and a 360 degree rotational axis in addition to the 3 axis but i am not sure. If anyone can point me in the direct of actual plans that would be helpful.....thanks!

[chuckknigh]

How about rotating the workpiece, rather than the head?

Wouldn't that be a workable solution for body plugs?

-- Chuck Knight