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Proof of Concept
Explorations that test ideas and functionality.
Demonstrates the functionality of the final product, but looks different.
Looks like the final product, but is not functional.
Appearance and function match the final product, but is made with different manufacturing methods.
Appearance, function, and manufacturing methods match the final product.
Desktop CNC HotWireCutter project is an effect of redesigning from scratch and lighting up the previous project I’v presented some time ago here on Kick Starter.
I'm first taken interest in CNC HotWire Cutters when i look for simply way of making wings for small RC model planes.
But CNC HotWire Cutters also a best tool to cut elements as 3d cliparts / home decorations /wall decoration/ letters, signs.
You can use your imagination and creativity and design your own logo, shop displays elements decorative letters and other 3d decorations.
Machine I’m presenting here is compact, desktop size, portable and really easy to use.
CNC HotWire cutter using light expanded polymers materials. Most of materials made in process of temperature expanding is suitable and can be cut on it. This means Styrofoams, insulation XPS boards, poly-carbonate / polymer sponges, etc. Use of this kind of material making our cut elements really light, it can be painted or coated with plaster, you can use them as base for vacuum molding, or as a core in home molding for metal forging as the material will evaporate on contact with molten metal
As you see I’m tried to keep design compact and fault proof. The aluminium box section making the construction light, stiff , and durable.
Machine is powered by 24V 4 Amps Power Supplier, has build in power regulator for Wire Temperature Control, and Smart Controller which running modified Marlin firmware, making usage of it really easy.
Thanks to Smart Controller machine is "Stand Alone" no PC is required to operate. You can load your g-code program on SD card insert it in Controller and execute it from panel of machine.
The wire is stretchered between two springs, and as power connectors works Crocodile Clips making replacement of wire trivial.
The smart controller can also be connected to PC by standard USB cable and Program can be executed form Software I’v develop for this machines Called BezierCAM.
BezierCam is another project I’v launched here on Kick Starter.
Its Free to non commercial use , Windows and Linux version are available for yo to download.
BezierCam allow you to use simple Clip-art in graphic format as GIF/ JPG / PNG etc. And quickly recalculate the clip-art into Paths ways for wire and into G-code program.
Then you can Simulate the process of cutting and Save you G-Code to PC HDD or SD-card or use build in sender and send the program directly to machine by USB connection.
The time of cutting process depends on material density, wire diameter and temperature set on wire.
Using thinner wire has it own benefits as is down's, Thin Wire allows to cut with much higher precision but it hard to get decent stretch of it, without breaking it. But the temperature capacity of it is much smaller, that’s forcing us to use lower feed speed to reduce dragging of wire in material.
Both parameters feeding speed and temperature can be adjusted in any moment.
I'm successfully used very thin NiChrome wire down to 0.05mm ( AWG 44 ) and Thick up to 0.5mm (AWG 20) The best effects I’m getting using 0.2mm Tungsten Wire it has much less thermal expansion, and better resistance characteristic.
This machine will allow you to use your invention & creativity in new way. You will really easy produce many wonderful projects, Very fast and in effective way
I Hope you enjoy this short presentation.
Below I upload design Overview & first test Videos showing BezierCam USB Link in action and Stand Alone Operation From SD Card.
Cutting Area 400mm by 400mm
Material thickness up to 140mm
Power Supplier 24V 4A.
Build In Voltage/Current regulator fro Manual Wire Temp Control can provide Up to 5A constant current.
Cutting speed depends on Material density, type of polymer, and wire temperature, and can be in range from 50 mm/min up to 5000 mm/min.
Power to Wire is Switched On/Off automatically when Cutting Process is Started/Ended.
Power to Wire can be switched ON/OFF manually from Control Panel.
Thank You for Your support.
Risks and challenges
This Project is based on previous. In ti I'm try to avoid many unnecessary elements, and make it simplest and lightest as possible not loosing durability and precision.
This allows me to cut manufacturing time and cost of single machine down.
Biggest challenge will be getting all orders for parts to arrive in close time.
Then put all together, and ship Rewards to my Backers in promised time.
Most of components I have locally available, box sections, Metal parts, bearings Shafts etc, only electronics and small pulleys & belts are sourced from abroad.
I'm already started printing plastic elements on my 3D printers to all can be ready before time.
In this project to types of rewards will be available pre-assembled kit , or Fully assembled Machine, as the shipment cost can be an issue, This will save on storage and shipments fees, And the Kits will be maximally pre assembled requiring minimum assembling.
Just 4 parts One need to be pushed onto rails and JST cable connector clip together, back Plate screwed to end of machine & One belt installed on X axis. Top Plate screwed down by 4 screws.
Full Video Instruction will be available before end of January.
You will receive pre assembled Kit,
Pre-assembled Sections of Machine minimum assembling should be evolved.
All mechanical parts.
Cables. Power + USB.
Fixtures for material Clamping/Holding.
SD-Card Containing newest version of BezierCam.
And Video Instruction how assemble it.
Your name will appear on Project Website as our supporter and will be added to BezierCam software supporters list.
Thank You for support.
As Reward you will receive fully assembled Machine
With All essentials.
SD-Card with BezierCam software.
Cables ( Power + USB )
Fixtures for material Clamping/Holding.
Your Name will appear on list of supporters on project web page, and will be included in List In BezierCam software.
Please ask for shipping cost to you country before this Pledge.