Project: OSIDIAS (SFF taken to the extreme)

[craigbru]

Great to hear that you will be making videos love the thread and im exciting of the progres you make.

The videos are fun to do, but I have to remember to take regular pictures as well. When I stream live, I hate stopping to pick up the camera.

Can't wait for more!

Thanks man!

[charles_h]

Wow Craig I'm really anxious to see what you create with that machine!

Good stuff!

[craigbru]

Wow Craig I'm really anxious to see what you create with that machine!

Good stuff!

Thanks Charles! Speaking of the machine, I've got a small update regarding it...

Since I have a habit of never being satisfied... I made a few changes to my CNC router. After my dry run with the picture in picture webcams, I started thinking about how cool it would be to add one of the cameras near the spindle itself. I thought it could capture the mill bit working as I machined. Well, in order to make this happen, I went ahead and got a $10 camera from newegg, and set out to find it a home.

I knew I had to get it as close to the spindle as possible, yet there could be no interference in the machine operation or safety. This was a must. The machine comes first, and these little extras second. So, as I was poking around with the cam, one thing became clear. My new mister bracket wasn't going to cooperate. I could either ditch the idea of a camera, or redesign the bracket. Well, I chose to make a new bracket. It is greatly simplified over the other one, but required the flexible metal shaft from a donor lighter. This shaft was the key to making everything work, as only this, a piece aluminum angle were going to be used in the new design. After a short while, the new bracket was in place, and I could move on the mounting the camera. This was even easier. I just needed a small aluminum triangle and a rubber washer... I removed the camera's original mount, and attached the aluminum. I then bolted the bracket to a free hole behind the spindle, and I was in business. So, shall we get on to a few pics?

Here you can see an overall pic of the machine. The new mister bracket, and the webcam behind the spindle are visible.



A little closer...





A few more closeups...









As you can see, there are no clearance issues of any kind. The machine is still just as easy to maintain, and I don't foresee any issues. Now all I need to do is get something cut!

[craigbru]

I managed to make a few cuts today guys. I was having a z-axis plunge problem which you will see in the first video in particular. (I've got videos 2 and 4 linked below). Apparently it's an occasional problem with Mach 3. I did manage to get it sorted though, and got all my cutting done. Take a look!

http://www.livestream.com/losiastech...9-a1e822fd22be

http://www.livestream.com/losiastech...4-c4d584e05332

[Xion X2]

Ha.. I like your idea about mounting a camera behind the spindle; that's a nice effect. The only bad thing is that the video (the overall video not just the spindle-cam) is so low quality that it's tough to see what's happening.

I'm not a pro at video by any means.. still learning it. But I've found so far that Youtube seems to stream better than anything else I've found so far and with good quality. But you're doing podcasts, and I'm not versed on how that works.

[craigbru]

Yeah, I do wish the quality were slightly better, but it's a trade-off from streaming live. I can record higher quality, but I just can't stream it. Also, higher quality recordings get a little choppy with fast movement... So, I tried to find a happy medium. One thing I may do, is record a higher quality locally, and stream lower... I'll keep playing with it.

[craigbru]

I came home from work today to find a nice sized box on my front porch. Inside was one of the last items I needed for setting up my Romaxx CNC machine. It was a VT6040 vacuum table that I had purchased from ebay seller dcad100. It measures 24.0”x16.5” x 0.8125", and was the perfect size for my machine. The vacuum table will allow me to hold parts in place without clamping. Should I need to clamp things anyway, there are M6 holes on the table that should easily allow this.

So, should we take a look at the table? Here it is as it arrived to me.



Opening the box revealed a very well packed table.



The table also came with a the necessary tubing for hooking up to a 2" vacuum line.



Also included was a solid rubber mat for blocking off unused holes during vacuuming, and a holed rubber mat that sits below parts that are being cut. The holed mat not only allows transfer of suction, but will help keep the end mill just above the aluminum table surface. These should be easily replaceable should the need arise.



The table looks to be of pretty good quality, and is well constructed.



Now finally, here is the table sitting on the machine. As you can see, it's the perfect size. All that's left is to get the vacuum lines hooked up, and it's ready for use. More coming soon!

[Raiden]

Great machine , i envy you

When is it going to start working ???

[Xion X2]

Looking nice. I like how detailed you are in your setup, thinking out every possible nuance.

Looking forward to seeing it in action. Was the vacuum table expensive or no?

[yngndrw]

I was looking at those vacuum tables for my CNC.

What kind of vacuum pump will you use for it and how will you deal with the liquid coolant ? Looks like the fit couldn't be any better.

[craigbru]

Great machine , i envy you

When is it going to start working ???

Thanks! I'm hoping to have everything running again the first part of next week.

Looking nice. I like how detailed you are in your setup, thinking out every possible nuance.

Looking forward to seeing it in action. Was the vacuum table expensive or no?

Thank you. I can be pretty picky when it comes to certain things. Maybe a little overly pciky. For example, I looked for days just to try and find a black parallel cable about 15' long. I never did find one and had to settle for gray... Lol.

The table was only a little over $200, and it was a full $100 cheaper than the standard aluminum top that you can get for the Romaxx. All in all, it was a very good deal.

I was looking at those vacuum tables for my CNC.

What kind of vacuum pump will you use for it and how will you deal with the liquid coolant ? Looks like the fit couldn't be any better.

I've got a vacuum pump from Grainger, and I'll cover that in my next update. There shouldn't be much for coolant issues. I'm using a mist that will evaporate pretty quickly. You are right though, the fit really is perfect.

[craigbru]

I had a little more time tonight, and was able to get the vacuum assembly finished. As of now, the vacuum table is completely ready to use. I am pretty happy with the way that things turned out. It's compact, easy to maintain, and fairly cost effective. Of course, none of that matters if the table doesn't perform as expected. Well, I'm happy to report that it performs even better than I had hoped. I know everyone is anxious to see how it turned out, so let me walk you through the rest of the setup process...

There are really only 3 major components needed in a vacuum table setup. The first is obviously the table itself which I covered in the last update. The second is the source of the vacuum itself. For this, I went to industrial parts supplier Grainger, and picked up a vacuum pump. I selected a two stage tangential unit capable of 97 CFM and 81.8 Hg vacuum. There were more powerful units available, but this one was an outstanding deal, and worth taking a chance. So, let's take a look at the pump...



Now, I should mention that although this is a vacuum pump, it's also a blower by it's inherent design. Unfortunately the only fitting for attaching a hose is on the blower end. That meant I had to get a little creative and epoxy a fitting over the vacuum hole. It was a simple fix, but just one more step I had to take before I could move forward.



Okay, now we've got two of the three major components out of the way. The third? Well, that should be easy. We've got to have tubing connecting the table and the vacuum pump. This shop vac hose kit offered the perfect solution.





As you can see the shop vac hose was a perfect match for the tubing adapter and splitter that came with the table.



Now all that was left was to route the tubing and hoses, mount the pump, and connect everything together. As you can see, the whole assembly is pretty clean and simple.





At this point I was pretty anxious to kick it on and do some testing. I'll try and get some video of that up in the next day or two, but as I mentioned above, I was very happy with the results. I could lay a block of wood in the center of the table, and with the pump running, it was surprisingly hard to move laterally. Keep in mind that this was without blocking off any of the other holes in the table. Doing so would increase the vacuum significantly. I'm pretty confident that as long as my feed speeds are appropriate, and my end mills are sharp, nothing is going to move while vacuum is applied. The only way to know for sure is to actually cut something, and I'll be doing that very soon!

[craigbru]

Well, here it goes guys. After more than a year of planning, I've decided to officially to start Project OSIDIAS. Granted, I still have other projects I'm still working on, but I don't want to delay this any longer. I can't promise daily updates, but I have a feeling you all will keep motivated to keep my work as updated as possible.

OSIDIAS will take everything I've learned from my Rogue project, and double it, in both scope and ambition. I've got some pretty unique things I'll be attempting here, and I've got no assurances that everything will work out as I've planned. That doesn't matter though, as I enjoy the challenges of problem solving on the fly. Even though at this point, almost every detail of the case is planned, there are still going to be things I decide to change. However, due to the way the case is designed, there are certain things that must remain set in stone. The overall exterior of the case and the carbon fiber shell for example.

So, where do we begin? Well, for those that may not have been following along up until this point, this video gives the best project overview. If you've got 20 minutes to spare, this should catch you up to speed.

Now, although this is the first official post of the project, I've only got a few pics to show you. Don't worry, I've got more incoming, but I this should get things started.

This case will be the first time I move away from aluminum as my primary construction material. There will still be plenty of it in this case, but I figured it was time for something more exotic. That's where carbon fiber comes in to the picture. Actually, carbon fiber, as well as a carbon fiber/kevlar blend. The carbon fiber will be placed around molds that I'm currently building, and them vacuum bagged. This is a proven technique for manufacturing, but the first time I'll be attempting it. There aren't many computer mods made from CF, let alone molded as in what I'm trying, but that's where the fun part comes in! I've got to give full credit to MKmods for his advice and input regarding working with carbon fiber. With any luck I'll not end up with a very expensive mess on my hands...

I mentioned having to make the molds, and that's where the following pictures pick up. Thanks to the help of my Romaxx CNC machine, I was able to accurately cut out a few pieces of the OSIDIAS core. These pieces will sit in the center, while an aluminum 'clam-shell' sits around it. After the carbon fiber and vacuum bagging, the idea is to push the center core out, and then remove the shell from the inside. This will leave a solid CF case, from which I will make the needed cuts.

Here are the blank pieces of MDF ready for the Romaxx CNC.



After the CNC cut...





And finally, I've got a stack of them.



Next up, we've got the core assembly!

[alphadog009]

wow this is one professional and epic build! ive been recently looking into building my own cnc machine and i must say that if i could build something about 1/100000 as good as that machine i would be happy! love your idea with the livestream as well and will definitely check that out when i can to get some ideas! good luck with the build and cant wait to see more!

[craigbru]

wow this is one professional and epic build! ive been recently looking into building my own cnc machine and i must say that if i could build something about 1/100000 as good as that machine i would be happy! love your idea with the livestream as well and will definitely check that out when i can to get some ideas! good luck with the build and cant wait to see more!

Thank you! The CNC was a great addition to the shop, and I'll be using it every opportunity I can. It's opened up a whole lot of design possibilities for me and future projects.

The livestream is still a work in progress, but I'm hoping to get it all sorted soon!

[LogAn'sRun]

Yeah, I do wish the quality were slightly better, but it's a trade-off from streaming live. I can record higher quality, but I just can't stream it. Also, higher quality recordings get a little choppy with fast movement... So, I tried to find a happy medium. One thing I may do, is record a higher quality locally, and stream lower... I'll keep playing with it.

I've had great success with Vimeo. Give it a go, plus if you have really hi def you can pay for a pro account and then load whatever size file you want.

[craigbru]

I've had great success with Vimeo. Give it a go, plus if you have really hi def you can pay for a pro account and then load whatever size file you want.

My overview video is on Vimeo, and I do like the service quite a bit. I'll definitely be adding more content as things get rolling here.

So, how about another update?

My last post left off with the cut MDF pieces for the core of the case. What I needed now was some simple way to fasten those pieces together, while still providing strength. I went round and round with possibilities until I decided on the following method. It all started with a trio of 22mm holes courtesy of the Romaxx.



Thanks to the CNC's accuracy and repeatability, I ended up with 6 pieces just like this.



With the first piece laying down, I tapped 3 sections of PVC pipe into the holes. The fit was just tight enough that there was no movement once in place, but taps with a hammer could still allow any needed adjustment.



Now finally, here is the assembled core. It's lightweight, yet very strong. The PVC pipe not only serves to hold the structure together, it also has a secondary purpose. Since the carbon fiber will be vacuum bagged, the pipe will allow for pressure equalization between the front and rear of the mold.



With the core done, I'll be moving on to the 2 part aluminum shell that fits around it. Thanks for reading!

[josk1]

not reading the text at first i was wondering what the f#####K you wanted to do with these wood-parts
good luck folding the aluminum, man!
can't wait to see your upcoming work

[craigbru]

Haha, I suppose it would look a little odd with the pics taken without context. I appreciate the kind words though! I'll have an update with the aluminum tomorrow morning.

[xxrabid93]

I can't wait to see where this goes! I love super small builds. If i can get some more $, i plan on doing one, but probably nothing near the amazing design of this!

[craigbru]

I can't wait to see where this goes! I love super small builds. If i can get some more $, i plan on doing one, but probably nothing near the amazing design of this!

Thanks man. SFF builds are just more fun for me.

So, let's get this updated!

With the core of the mold done, it's time to get some aluminum wrapped around it. It's a pretty simple concept, but I need perfect execution. The aluminum needs to fit the MDF perfectly, as it ultimately will determine the shape of the carbon fiber on top of it.

I'm starting by using some AC Ryan 1mm sheets that I had lying around. I've had these for quite some time courtesy of the Rogue project's bit-tech Mod of the Month win almost 2 years ago already. I figured it was time to put them to use.



One of the newer pieces of equipment in my shop is this metal brake. I've retired the little 18" unit I had, and moved up in the world. To say that it's a huge improvement, is understating the obvious. So, I marked out the aluminum, and slid it in place for the first bend.



A second bend later, and things are looking good!



An additional 4 bends brought me to this.



A quick test fit, and it was looking pretty good. Well, good enough to move on to the other side. At least for the moment...



I made the second panel, and after evaluating it's fit, I decided to remake the first one. Ultimately I just wasn't happy enough with the way it fit the contours of the MDF core. It couldn't have been more than a single millimeter off in the way that it fit one of the edges, but it was still too much for me. I sometimes tend to set standards for myself that seem unreasonable, but when something is bugging me, I just can't let it go. So, the red panel is gone, and it's been replaced with blue and green...



Since I was pretty happy with the fit of the new panels, I now needed to get them marked and cut to fit. I need perfectly flush mating on the top and bottom joints, and I'll cover that in the next update.

[craigbru]

Haha, there's nothing like the smell of a warm Dremel on a beautiful Thursday night... With my last update, I was ready to trim the top of the aluminum shell down to size. A few minutes of cutting and filing left me with a prefect fit. It's absolutely straight with no gaps.



Now it was time to do the same thing on the bottom. I always mark first with either a pencil or fine point Sharpie, and then follow up with tape. When I cut, I get as close to the tape as possible, then finish up with a file. I find that it's easier to follow the edge of the tape, than it is any regular line.





Once again, after cutting...



Okay, so what's next? With the aluminum shell done, I've got to prep for layering on the carbon fiber. Since I'll have multiple layers basically rolled on the mold, I needed an easy way to apply the CF. The following method is what I came up with. I've got a pair of sawhorses and a piece of aluminum channel through the center pipe on the mold. This will allow me to roll the mold in to any position, yet the square planes of the channel means that it won't roll away when I don't want it to.



Now let's take a look at my box of goodies from Aerospace Composites. I've got a vacuum generator, check valve, associated vacuum bags, and peel ply. I'll be using all this to ensure as flawless a finish as possible.



At this point I decided to do a small resin test. I've seen far to many instances where resin doesn't set, and I want to make sure I've got a workable ratio. The last thing I need is a mess on my hands. Up next, the fun part!

[LogAn'sRun]

wow, looks fantastic! I've always been curious with bending, how do you know where to bend and at what angle?

[phinix_mike]

That is pure perfection, Craig! Amazing start of new project, I'm happy to see the first bends Sweet model shaping.
One question - what is "sawhorse"? Don't know that word

[Waterlogged]

craigbru, Off to an awesome start.

I get the feeling that even though you like the new brake, your gonna wish you'd gotten a box & pan model with the stuff you get yourself into.

That is pure perfection, Craig! Amazing start of new project, I'm happy to see the first bends Sweet model shaping.
One question - what is "sawhorse"? Don't know that word

Usually 2 are used as a place to cut long pieces of wood or put a sheet of plywood on them at a job site and you have a makeshift table.