Series 1 3D printed rotary duplicating machine

3D printed machine which carves, duplicates and produces objects

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My first new machine for 2017-The rotary duplicator. Designed for makers who want to make!
(Made just for the HaD contest!)
This machine carves wood and make shapes. It can be operated in three modes:
1. As a CNC guided carving tool.
The rotary cutter is guided by raising and lowering the tool against the work through code in CNC mode while the X axis moves the cutter along the length of the work. The cutter speed, the axis speed/direction and the rotary speed are all used to produce a new part.

2. As a straight line duplicator.
The top pattern is followed by a stylus which guides the rotary tool below against the work. The X axis sweeps back and forth and each pass lowers the tool bit deeper into the material making the process hands free and requires no controller.

3. Non concentric duplication.
The top pattern is perfectly synchronized with the lower work piece to produce off center, or odd shaped items. A timing belt assures the top follows the bottom.

This machine has a fascinating architecture and is a joy to watch. It uses simple inexpensive common parts, and despite the complex looking frame is fairly easy to put together and get up and running. It gives the maker the ability to not only create new parts but also duplicate them.

The X axis is using a small bipolar stepper motor attached to a leadscrew for carriage movements.
The cutting tool motor(5$) has a small chuck(2$) to hold 1/8 inch rotary tool bits and sanding drums to do the carving.
The motors are all driven using off the shelf speed controllers to accommodate various woods. It looks rather complicated as far as wiring, but its all very straight forward.
When running it looks like a living organism. Each motor is moving when and as it should and as material is removed the part takes shape.
It does make a bit of a dusty mess but containable. Does not make too much racket, mostly just the cutting motor. The printed parts consumed 250 meters of filament. The full set of mechanical/electronic parts cost about 25$. The base is acrylic and has a footprint of 16" X 5 " although some parts of the machine do overhang. This was by design to keep shavings from falling into the X axis lead screw below.
I have found that on softer woods a 1/4 inch band sanding drum works great and makes a satin smooth finish on parts. Maximum stock size for this machine is 2" square X 8 inches long.
This machine is scaleable-It can be made larger.
My goal is as always to design and make inexpensive 3D printed machines that make.

  • Motor selection for the duplicator

    castvee803/28/2017 at 01:29 0 comments

    I used several motor types building this machine. The twin spindle motors use a standard DC gearmotor with an extended shaft:

    This is the speed controller I used for running the twin spindle motors:

    I used this small bipolar stepper for the X axis and the toolbit height axis:

    This is the tool bit motor:

    This is the toolbit motor speed control:

    These motors are all widely available, common and very inexpensive(under 4$ each) and the controllers are as well.

  • Using the machine in CNC configuration

    castvee801/19/2017 at 01:30 0 comments

    In order for the machine to produce originals from code, the stylus must have a reference guide to rest on.

    I made this adapter from 2 3D printed ends and a piece of acrylic tube.

    The adapter loads just like a piece of stock material does as shown. It is smooth and slick and allows the stylus to glide nicely across.

    Since the tool feed motor raises and lowers from the stylus common frame, it now has a reference and home position.

    I also use this adapter as a "roundoff" template. It makes a nice smooth 1 inch round shape across the entire stock.

  • Assembly montage

    castvee801/16/2017 at 03:29 0 comments

  • Basic functions of the machine parts

    castvee801/13/2017 at 19:24 0 comments

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Tom Ogden wrote 01/22/2017 at 06:42 point

This tool is awesome, and I especially love the X-axis.  Very nice work!

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