My new CNC and AFDS panel

[Wendy]

Recently I have bought myself a CNC-machine.

My machine is a Colinbus, well actually I bought the DIY version. Comes in a build yourself package. Building was easy and after 2 days the machine was running, but that was all... it comes standard with a Ferm-router and with this router you can do nothing at all as I was about to find out. Trying to get results out of the CNC and until I buy a Kress I've mounted a Dremel on it and that was a real improvement.

After much trial and error and with the kind and patient help from Hessel I managed to get some nice results that I would like to show to you.

The pictures show you the building of an AFDS panel B738. Currently only the buttons are finished. Also you will see my first very bad resulst.:)

regards, Wendy


First picture showing very bad resulst with the Ferm-router
http://www.querit.eu/FS/AFDS/bad_ferm.jpg

This is much better with the Dremel-router
http://www.querit.eu/FS/AFDS/better_dremel.jpg

My machine
http://www.querit.eu/FS/AFDS/colimbus.jpg

All the parts that make up the AFDS panel, already a good engraved button
http://www.querit.eu/FS/AFDS/good_comps.jpg

All 3 buttons
http://www.querit.eu/FS/AFDS/AFDS_3_Buttons.JPG

All 3 buttons and the panel
http://www.querit.eu/FS/AFDS/Afds_buttons_front_3_buttons_panel01.jpg

Backside of the buttons
http://www.querit.eu/FS/AFDS/Afds_buttons_back02.jpg

http://www.querit.eu/FS/AFDS/Afds_buttons_back01.jpg

All 3 buttons completed
http://www.querit.eu/FS/AFDS/Afds_buttons_front_3_buttons.jpg

And lighted...
http://www.querit.eu/FS/AFDS/Afds_buttons_front_single_button.jpg

http://www.querit.eu/FS/AFDS/Afds_buttons_front_single_button_without_light.jpg

[Joe Cygan]

Great work! Very impressive.

[vybhav]

That is really wonderful wendy. How much did you invest in the machine?

[Jan737]

Hi Wendy,

Great job!!!
What letter type you use???

Best regards

Jan Geurtsen

[wannabeaflyer]

Hi Wendy, you dont hang about do you:-) nice machine and already quailty Work Big up Praises for the work done , i have my machine up and running and at long last invested in 2 pieces of must have software , Mach3 and Cut2d , to say i love it is an understatement Have only now after all these yearss Faffing about finally seen my DIY monster Cut material , for me at this stage i intend to use tje machine to make its on parts to replace some of the lets say not so well made elements of it self but already i can do PCB work and can see how much im gonna use this piece of Kit, so looking at the work you have done in ashort space of time is pretty impresive .. My baby does not look Pretty but cuts accuratly and will get better once i replace some of the parts for how shall we say More cosmetically appealing bits LOL:-) did you design your parts or get the files from some other source , What CAD package and CAM package are you using ?

[Wendy]

Thanks for you nice comments

@vybhav
The price of the machine was a little bit more then 2000 euros. But without extra software and replacing the router you cannot do much more than drill a hole. I was lucky that I stil had a Dremel so I plan to buy the Kress next year.

@jan737
The fonts I use are Futura fonts in different styles.

@wannabeaflyer
I have 2 cad packages: ABViewer and Autocad


Kind regards, Wendy

[t1dUs]

looks great
by the way: what material are you using for the panels??

[Wendy]

I have a few different materials depending on what to do. For panels white acryl. The buttons are made of transparant and white acryl.

Kind regards, Wendy

[Jan737]

Thanks for you nice comments

@vybhav
The price of the machine was a little bit more then 2000 euros. But without extra software and replacing the router you cannot do much more than drill a hole. I was lucky that I stil had a Dremel so I plan to buy the Kress next year.

@jan737
The fonts I use are Futura fonts in different styles.

@wannabeaflyer
I have 2 cad packages: ABViewer and Autocad


Kind regards, Wendy


Hi Wendy,

Are they true type?
And where can I find these type?
Best regards

Jan Geurtsen

[Wendy]

You can find the fonts here, thanks to Hessel who gave me this link:
http://members.fortunecity.es/todofuentes1/index/descarga/f.htm#fu

In your CAD drawing you have to explode every letter and remove all lines you don't want.


Regards, Wendy

[Westozy]

Hi Wendy, that is great work, well done. I have also just invested in a CNC machine and I'm having great fun with it.

http://www.mycockpit.org/photopost/data/575/medium/CNC_001.JPG

After seeing your work I think I will have to revisit the panels I have already made in my 737 and re do them all!!!

Regards, Gwyn

[Wendy]

Hi Gwyn,

I'm always admiring your work and followed your thread about your CNC machine. I'm pretty sure you will soon make parts you could only imagine in your dreams.

CNC is a lot of fun and I enjoy it very much. The biggest challenge for me is drawing the part in a way the machine can make it.


Kind regards, Wendy

[Westozy]

Hi Gwyn,

I'm always admiring your work and followed your thread about your CNC machine. I'm pretty sure you will soon make parts you could only imagine in your dreams.

CNC is a lot of fun and I enjoy it very much. The biggest challenge for me is drawing the part in a way the machine can make it.


Kind regards, Wendy

Thank you Wendy, it's a buzz to be rewarded wth comments like yours! I know exactly what you mean about drawing, CAD seems to defy all logic! I'm starting CAD lessons next week and hopefully that will really speed things up for me. The engraving side of things seems pretty easy and I'm getting some good results. I bought VCarve Pro 5 and cut 3D software which is really good.

Cheers, Gwyn

[Jan737]

You can find the fonts here, thanks to Hessel who gave me this link:
http://members.fortunecity.es/todofuentes1/index/descarga/f.htm#fu

In your CAD drawing you have to explode every letter and remove all lines you don't want.


Regards, Wendy


Hi Wendy, thanks for the link.
I'm experimenting with exploded text, but how can I remove the lines I don't need.
If I try, complete parts of the text going lost.

Best regards
Jan Geurtsen

[Wendy]

Sometimes you have to explode text or parts of text multiple times. I'm just doing it until I can delete the line I don't need.

See this thread:

http://www.elektor.nl/forum/forum/actuele-projecten/profiler/maak-alle-letters-en-fonts-makkelijk-freesklaar.272868.lynkx?highlight=autocad


Wendy

[Hessel Oosten]

Exploding is 2 times:

1. Express tools: Explode TEXT
2. "Normal" Explode.

Select thereafter all the wrong lines from: * right under to left above *.
This goes quicker because all the wrong lines a double (!).
With this type of selecting in AutoCad you have them * both in one selection*.

Hessel

[Matt Olieman]

Hey Wendy.... :) :) :) I missed the start of this thread. WOW, what wonderful work, I'm Soooooo impressed. Thanks for the pics, I love them :) :) :)

BTW, if you haven't met Wendy personally, she is brilliant and fascinating to talk to. I'm glad I had the opportunity. :)

[mondo50m]

Awesome work with the CNC machine....my dremel seems to be getting sloppy in the main bearing and needs replacing....where does one get the Kress motor? I have been online to look at their site, but there is no 'where to buy'.

Milt

[Wendy]

Thanks Matt, same for me it was a pleasure talking to you.


Milt, here is a link to a specific CNC shop. It is in Nederland but that should not be a problem you can order online. Scroll down the page and you will see the different types of Kres routers.

http://www.damencnc.com/damencnc.php?dir=cpt&PHPSESSID=182e219406a261012a041d90db42a2fc&langId=EN&idType=9&PHPSESSID=182e219406a261012a041d90db42a2fc

Regards Wendy

[Wendy]

Here it is...

After a lot of trial and errors I've finally finished my first AFDS panel with the help of my CNC. There are still a few minor things that can be better but for now and being my first home made panel, I'm very happy. The text on the buttons is very sharp and only just cut through the paint and a little bit in the acryl. You can just feel the engraving a little bit.

The backlighting is done with SMD-Leds mounted in small cutouts directly in the panel. Wanted to do this at first with a printed circuit board but there was no room in this small panel so I've soldered tiny wires to also tiny SMD leds.

For the buttons I've used standard momentary pushbuttons available through the local electronics shop. They also exists with a make contact.

I enjoyed making this panel myself and already started drawing the next panel.

Take a look at the photo's...


Kind regards, Wendy

http://www.querit.eu/FS/AFDS/AFDS_Finished_Front.jpg

Backside of the panel with the wiring
http://www.querit.eu/FS/AFDS/AFDS_Finished_Wiring.jpg


http://www.querit.eu/FS/AFDS/AFDS_Finished_Side.jpg

The buttons I have used
http://www.querit.eu/FS/AFDS/AFDS_Finished_Button.jpg

Soldering the SMD leds
http://www.querit.eu/FS/AFDS/AFDS_Finished_Wiring_SMDLeds.jpg

[t1dUs]

WOW
Astonishing results!! Keep up the great work and keep us posted of your whole project :D

[Matt Olieman]

Amazing work Wendy, wonderful job. Thanks for the pics :)

[Joe Cygan]

Great work Wendy!

[Westozy]

That does it. Now I have to rebuild my MIP from scratch!!!
Seeing your results has just caused a major rethink for my B737!
Excellent work Wendy - Kudos to you!

Here is some of my own progress with the assistance of Darryl Hackett...
http://www.mycockpit.org/photopost/data/658/medium/Aerosim_009.JPG

I fitted the old Matrox Parhelia video card from my first sim pc to the cnc's pc. I can now display the Mach 3 and VCarve Pro software at the same time which is pretty neat!
http://www.mycockpit.org/photopost/data/575/medium/Aerosim_002.JPG

Here's the new lathe, installed and running, it's 38C (102F) in the workshop so it's too hot to have a play :-( I'll just have to wait til midnight!!!
http://www.mycockpit.org/photopost/data/575/medium/Aerosim_014.JPG

Gwyn

[Wendy]

Thanks all for your kind words. Sorry for you Gwyn that you have to redo your panels. :rolleyes:

To get the engraving sharp I only cut 0.03 mm deep in 1 round, if that is not enough I'll do another round +0.01 mm and continue like this until all letters are crisp sharp. Sometimes it takes time but the result is very good.


Regards, Wendy

[wannabeaflyer]

Hi Wendy Just adding my Praise to the stuff you guys are doing, can i ask what size and type of cutters your using for your panels ..when it comes to speeds and feedrates do you have a look up chart of some sort or is it trial and error for want of a better phrase. during some of my recent tests i have found that my Router spins way too fast for some material ( MDF is great stuff but a bugger in terms of eating cutters and dust ) the bits you have made so far seem very precise so just wondered how you sorted those elements out . my prefered cad package is inventor ( i use it at work ) and can quickly draw up a 3D model which i then export as a DXF file to CUT2D that software ( Brilliant )then Spits out the CAM data to MACH3 and away i go, but sometime i mess up with the Feeds :-(. Then have to change them manually whilst the machine is cutting . Thanks for the tip regarding Engraving Text will put that to good use Cheers Guys n Gals :-),

[Wendy]

Hi Wannabeaflyer,

Concerning the cutters... I have the following bits used in this panel:
-2 mm endmil, with this one I have cut the panel and the holes. I used it also to cut the squares around the buttons. They are made separately and then glued into place.
-V-shaped (don't now how you call it) used to make the horizontal line and the vertical line between the buttons.
-0.2 mm engraving bit, for all the lettering

For engraving I use the lowest possible settings, so 1 for speed (yes it is slow) and 1 for feedrate. For the router, lowest possible tr/min.

For cutting I use settings between 5 and 10, depending on the type of material.

Hope this helps you.

Regards Wendy

[mondo50m]

Excellent work with the CNC machines. Would be nice to start some sort of sticky or thread where we can exchange g-code files with each other. Or even just set up a new category in the file library. I use Cut2d and Mach3 with my machine. Mine is a simple homebuilt using a Dremel 300 as a motor. Gets the job done. Working on a larger machine along with everything else.

Milt

[Westozy]

Excellent work with the CNC machines. Would be nice to start some sort of sticky or thread where we can exchange g-code files with each other. Or even just set up a new category in the file library. I use Cut2d and Mach3 with my machine. Mine is a simple homebuilt using a Dremel 300 as a motor. Gets the job done. Working on a larger machine along with everything else.

Milt

That's a great idea Milt, a CNC forum with Gcode file sharing, I'll talk to Matt about it!

Regards, Gwyn

[autocadplease]

It is a good idea in principal, but unless you have very similar machines with the same spindle, feeds, bits, offsets, etc G-Code is not that generic - it is actually quite specific for each job and machine. Exchanging DXF or vectorized files would be very helpful though.

[mondo50m]

I agree 100% with autocadplease, I have had conversations with a couple of the home cnc users on this site and they are running cut2d and mach3 as I am. These files are totally interchangeable as they are using the same gcode generator and post processor as I am. DXF file exchange would be better as each user could generate his own gcode file using it. Each file that I upload will contain a short note on what type of material I used, bit size, and approximate cut speeds and spindle speeds.

Milt

[Westozy]

Hi Guys,
I can supply .DXFs for any type of gears now, I appeared to have got my head around gear cutting ok. I'm now using gears for throttle/potentiometer drives and trim wheel/indicator drives!

Gwyn

[mondo50m]

Are you using a cnc router or lathe for the gear cutting? I have been trying for some time to cut gears on my cnc router without much luck.

Milt

[phil744]

Hey Wendy,

Well, wow what can i say, i remember you telling me what you were planning one cold November morning outside in Lelystad and im speechless with the results you have had so far, looks like i better pull my socks up and get on with things, all this talk of CNC is making me rather jelous cause im still without but that will change soon :)

You keep up the fantastic work and keep us all posted :)

[Wendy]

Hey Phil,

Thanks for the kind words. Such a comment from you makes my day.

I still remember our nice chat and hope you will have your CNC very soon. It sure is a lot of fun to work with.


Thanks again, Wendy

[Westozy]

Are you using a cnc router or lathe for the gear cutting? I have been trying for some time to cut gears on my cnc router without much luck.

Milt

I'm using "Involute" software to cut gears on the CNC, it's brilliant and really easy to use. I made the trim indicator drive gears for my A340TQ today. The CNC was cutting the gears while I made other parts on the lathe. The A340TQ is almost finished, not much more to do. I'm not looking forward to painting it, I don't like painting but I just bought an airbrush and I'm hoping that helps.
Phil - CNCs are awesome, it's a new hobby!
http://www.mycockpit.org/photopost/data/658/medium/TQ_004.JPG
http://www.mycockpit.org/photopost/data/658/medium/TQ_002.JPG



Gwyn

[Wendy]

That's going to become a very nice throttle.

Those gears also look very good Gwyn, have to try this out sometime. What tool have you used to mill them ?


Regards, Wendy

[Westozy]

That's going to become a very nice throttle.

Those gears also look very good Gwyn, have to try this out sometime. What tool have you used to mill them ?


Regards, Wendy

Hi Wendy,
I used a 1.5mm end mill and the gear cutting software is available here - http://www.realhamradio.com/gearhome.htm It is fantastic and a good buy at AUD$86.00! The software produces .DXFs which I convert in VCarve Pro to GCode. I have cut 2D & Cut3D aswel but I haven't had a play with them yet.

Gwyn

[spitfire9]

I just about have the Zenbot CNC set up. Got an old computer with a printer port and WinXP to run it.
I just purchased Mach3 and it has a free version of LazyCam with it.

I am new at Cad software so I was wondering what Cad software would be good for a beginner ??

Also has anyone had any experience with Lazycam ,,would that 2Dcut program be better??

Thanks.
P.S. I think a file sharing area for cad would be a great idea.

[mondo50m]

For a beginner, I would recommend Cut2d. It will cost you $150.00 which is cheap for what you will get.... It will take your DXF file and make it into the mach3 gcode file for you. It is very easy to learn and I have used it exclusively to make my panels, even the drawing part. It is not a drawing program per say, but remember, when building panels, we only need circles and squares. When you are ready, I can email you some of the gcode fies that I have made from cut2d for mach3. Send me a pm.

Milt

[spitfire9]

Sorry double post.

[mondo50m]

With the cooperation of Matt, there is now a file share section in the file library. Go all the way to the bottom of the page....not much there yet, but it is a start. I will be adding to it in the next few days.

Milt

[spitfire9]

Mondo50m,, thanks,, when I get everything running I'll take you up on that offer.

[maliga00]

It`s looks fantastic!!!. Gwyn, what kind of material did you use in gears?
Thanks.
Alberto

[Westozy]

Hi Alberto, the grey gears are PVC but they can be cut from anything type of plastic or acrylic really. My new TQs will have partial gears cut into the throttle levers as part of the form, I am about to start on a 777 TQ for a customer and I will probably document the build.

Cheers, Gwyn