The Project Pad

Guys,

I'm trying to take my project to the next level. I'm currently learning Autodesk 123d software, so the easy parts to model I'm learning.

I'm basically looking at 3d scanning several parts, and then getting them CNC cut from foam to use as plugs for Carbon Fibre goodness and casting purposes.

Not sure what this ball park costs. I know it will obviously vary by size and complexity of the part being built.

Does anybody have any input on this stuff.

Cheers,

Craig Cook.

How big are you talking. A lot of DIY foam cutters have been built. I looked at is semi seriously while in school and you could cut foam only with fairly small motor controls on 5 axis. The hardware is cheap compared to 5 axis CAM software for generating tool paths. Entry level 5 axis stuff is about 10k. The hardware part could be assembled in the 4-6k dollar range depending on size, and require a few long weeks to get it together.

For cutting smaller foam pieces, a regular mill can do a pretty darn good job. My CAM software for instance cna take a solid, then section into 1" layers. so you could basically build a fender in 1" slices, then glue them together for a 3d part. This is fine with foam as nothing comes off the mill ready for layup.


Hank

Thanks for the reply Hank.

Size will range from engine covers and such to maybe complete a dashboard. I'm not currently in the position to
build my own cnc for foam cutting, but I have thought about it. Mainly trying to ballpark getting stuff scanned etc.

This kind of technology along with 3d printing is going to make us car guys so much happier, and the finished parts
so much more detailed.

Again thanks for your reply.

Cheers,


Craig

Ill post up some pictures of my router table in action. It fits full 4x8' sheets and has about 8 inches of z travel. It isn't rigid enough to cut steel, not can the 8-24k rpm spindle go low enough for steel, but it chew up aluminum. It would cut foam without blinking and have great resolution. Like I said eariler, I can make a model of a dashboard in CAD, section into 5-6 layers in software, cut those layers and then make a buck by glueing the sections together. This is something that is done often, even with bigger machines.

Here it is cutting some engine mount parts

Nice Hank! It'll be cool to see all the new toys at BBQ '13

If you're looking for any kind of dimensional accuracy - I would not suggest 123D Catch. There is another product called AgiSoft Photoscan, but it is about $150 (not too bad IMO).

If you really need accuracy, you could laser-scan, but of course that is $$$. I use all of the above on a day to day basis and 123D is by far my least favorite. I would suggest building the model from the ground up, as 123D will introduce a lot of headaches. Even using sketchup will save you time over using 123D and then trying to correct for the extra geometry and potential issues.

Hope that helps.... If I understood what you're trying to do correctly (model molds for casting) - I would use a hand-modeling software rather than photo-scanning. If you already have the molds, the only way to get a good, accurate model is with a laser scanner.

I've only routed foam a few times... mostly wood:


Used many different laser scanners though: here's a FARO



It will be cool to see what you do with it - I just began an endeavor to model molds for T44 200 20v mudflaps in CAD, route them out of wood, and then cast them into rubber.

Many thanks for the replies guys.

Hank I'm really impressed with your tools, setup etc. I wish I were in your positon. Lot's of hard work for sure,
but it looks like it's paying off.

Fenris thank for the reply also. I have alot to learn, and a very steep hill to climb. This technology really gets me fired up. I will continue reading, learning in the hope that one day I can make up pretty much any part that I can think off.


Please keep posting anything that you think is relevant.



Craig.