For about 15 years, I have wanted to try my hand at CNC machine construction. Back then, there was limited Internet to help me and my friends working in this space told me all of the components were well out of reach price-wise of the average guy, so that was just one more crazy dream put on the backburner. (It went back there with home foundry, welder, mill, lathe, homebuilt airplane, a few software ideas.) I also did not have the space to build any of this.
Now, the prices have come down on these things and the Internet has allowed me to learn that there are gobs of crazy guys like me that want to do, and have done, all of the same things. I built myself a dedicated, heated and air conditioned workshop (aka "man cave," "hiding place," "mad scientist lab" - 36' x 20' with 9-1/2' ceilings) to feed my insanity. I am an engineer with extensive CAD knowledge and 20 years of work experience but not as much real practical experience turning ideas into reality and I use the phrase "I don't know" more than anything except possibly "Sorry, honey." I welcome all help and ideas. I have been impressed by the things I have seen people on these forums do and with everyone's helpfulness.
My objectives with this machine:
1. Primarily will do woodworking projects - plywood, hardwood, but I also want to cut large foam pieces (think single seat aircraft fuselage mold plug and wing sections). While I am at it, I want to be able to machine aluminum, but I understand there are also limitations.
2. I need it to fit in my shop and not be the only thing that fits in my shop.
3. Regarding number 2, I can make this happen more easily if I design the machine such that the table is also useful as a work table when I am not committing CNC so my concepts have started gong this direction.
4. I want 4 axis so I can cut more than just profiles and one side. See comment on aircraft fuselage.
5. Budget. I know this area is sensitive to some but I talk pretty freely about it. The Probotix guys here in town have told me that they will put together 4 axis electronics and motors (1150 oz. in) for me for about $1800. It's worth it for me to not have to try to manage all those little electrons that I can't see. I have run through about 8 concepts and all put me between $6-10k for the total cost (including the previously mentioned $1800). I would rarther stick closer to 6. The alternative is to delay it. I have a bonus check, tax return, and I am selling a motorcycle to help me finance this year's insanity but the wife is and kids are claiming some of that.
Where I am:
Configuration:
basic moving gantry style with Y straddling table and connecting outside of the X so I can hide the rails and be able to sue the table for other things.
Size: total machine envelope will be around 11' long (x), 6' wide (50' of actual Y capacity), about 8' high to accommodate 22' Z travel and room to spin something on the 4th axis
Materials:
Rails: I was planning to go with Pacific Bearing IVT V rails and carriages, but if something cheaper and capable comes up, I am open. I am excited by this prospect of 18' Thompson rails that I saw posted yesterday and have contacted that guy to see how I can snag those. It seems like the CNC Router Parts bearing carriages and cold rolled steel end up costing almost as much as the IVT stuff, at least not enough price difference to send me that way and they will not have the same strength.
Core machine Body:
Current thinking is aluminum extrusions. I had 80/20 buy me lunch and bring their demo van, but I am leaning toward the Misumi extrusions. Another guys said they make the starightest extrusions and they configure and deliver really fast for you. They also fit the IVT rails. I have also kicked around steel weldment, but that means buying a welder and learning to weld first. I want to do both but cost and time will create a delay.
Machine base:
This is where I have gotten pretty hung up. I have created CAD concepts like Joe's Hybrid using UniStrut, 80/20, LVL (laminated veneer lumber - think really thick plywood), steel I-beam / tube (like MechMate), MDF, plywood/foam sandwich, fiberglass sandwich. All of these are expensive. Welded steel seems like it may actually be the cheapest option once you make the structure stiff enough to support what ends up being a 330 lbs+ Y-Z unit. I found that all the connectors add up really fast on the options that require no welding.
Now that I have consumed the whole thread with one post, I am interested in people's input. I will post some CAD images later.
Thanks,
Andy