Techno is proud to introduced the PanelMaster Pro Series CNC Router. Designed specifically to meet the demands of nested-based manufacturing, the PanelMaster Pro is constructed of large heavy tubing that is welded and stress-relieved, the perfect foundation for our precision drive system. Comprised of precision ball screw drives on all three axes, THK rails and bearings, high-speed closed-loop servomotor and drives, the PanelMaster Pro’s precision drive system ensures minimal maintenance, machine longevity and superior machine performance.

A unique new feature of the PanelMaster Pro Series is the double beam assembly which includes four linear rails, twelve linear bearings, double ball nut, joined together with a welded reinforced cross beam assembly. This engineered assembly optimizes the machines performance resulting in overall superior cut quality. All models come equipped with a 10HP Automatic Tool Change Spindle with 7 position tool station, (6) zone vacuum table, and 10HP Rotary Vane Vacuum Pump. Additionally, this machine comes complete with a new computer system that has Techno’s Windows PC-based CNC Interface installed and configured before the machine is shipped. The new PanelMaster Pro series follows Techno’s traditional easy-to-use and operate philosophy so that customers can be up and running as quickly as possible, getting a return of their investment.

http://www.machinetoolsonline.com/content/news/article.asp

The furniture router you purchase should be reliable and durable so it handles all of your carving and cutting needs with minimal problems. Make sure the cnc router for sale is sturdy throughout: on top, inside, and underneath. You want the parts that do the bulk of the work to be durable, and easy to maintain.

If the material you are cutting is very thick, a furniture router may not be able to cut it in one pass, and will need to make multiple passes to get the job done. Try some tests to ensure the router can cut through the wood you will use and that cuts are smooth and accurate with minimal vibrations.

Make sure you are comfortable with the software you select for your furniture router. It should be fairly easy to program and to fix errors. The best way to become accustomed with the software is to take advantage of the training that most CNC router vendors offer. Depending on your computer and design knowledge, training may only take a couple of days.

CNC Router For Sale: Cost will be a major factor in purchasing a furniture router, but you should consider your total cost of ownership. A less expensive model might make sense now, but if it doesn’t provide enough speed or capacity for your future needs, you may need an expensive upgrade down the line. You also need to consider what short-term and long-term benefits the unit can provide, such as reducing your operating expenses and labor costs.

http://www.buyerzone.com/industrial/cnc_routers/tmm-furniture-router.html

Get more bang from your equipment buying buck by investing in a CNC router. These routers have a number of different uses that will come in handy around your work room, including cutting out shapes for woodworking and doing engraving jobs. What’s more, they get the job done with an incredible amount of efficiency and accuracy, more than any human worker could accomplish.

CNC Routers - What Can They Do For You?

Have you been passing on jobs because you think you don’t have the time or the skill to get them done properly? This is where a CNC router can come in handy. Do you need to create an elaborate carving in wood, or combine wood and metal into an integrated design? What would take you months, if you could get it done at all, can be accomplished in a matter of minutes with a router.

For its accurate carving abilities, CNC routers have become a must have tool for furniture manufacturers. However, there are even more uses you can find your router. CNC lettering - engraving completed using a CNC machine - is an extremely efficient way to add a new capability to your work room. CNC letters allows you to personalize things for your customers in a just a few minutes, with the help of a software program.

Buying a CNC Router

CNC routers may be great, but they can cost a pretty penny. Increased demand in recent years has caused prices to fall somewhat, but a brand new router is still in the several thousand dollar range.

That price tag doesn’t mean you have to give up, however. You can buy a used CNC router for significantly less than a new one. In many cases, a used router can be less than half the price of a new one, which means you might be able to get one into your work space for less than you imagined.

A word of caution about used CNC routers: many of the them are actually reconditioned routers. That means that they may have been damaged in the past, and they have been restored to working condition. Using a reconditioned router is fine and a good money saving option for many people, but it pays to make sure you speak up and learn the history of your router before you shell out your money. A good reconditioner will have no problem offering you a limited warranty, so if someone is trying to sell you a used router with a warranty, beware.

http://ezinearticles.com/

Onsrud Cutter LP, the leading supplier of CNC router tooling, announces the introduction of the Tuff Core Compression. This unique 3/8″ diameter tool utilizes a dual-grade carbide that incorporates a tough inner core for added strength and a wear resistant outer shell for longer life in abrasive materials.

The “Tuff Core” allows feed rates to be increased up to 155% over conventional 3/8″ diameter compressions. Higher yields are also possible as standard ½” compression tools can be replaced with the stronger 3/8″ Tuff Core tool.

http://news.thomasnet.com/fullstory/519889

CNC routing machine has helped a manufacturer of polyvinyl chloride significantly improve quality and productivity - as manual drilling operations were slow and hole sizes and locations varied

A new economical, computer numerical control (CNC) router has helped a manufacturer of polyvinyl chloride (PVC) significantly improve quality and productivity. D L Manufacturing makes MxVdoors that last longer in loading docks because they can be knocked out of their track without damage. Previous manual drilling operations on the doors were slow and uneven feed rates caused hole sizes and locations to vary.

Wendell Moulton, engineering manager, looked at large machining centers but found they were very expensive and much heavier than needed to cut PVC.

Then he located a CNC router for only a fraction of the cost that automated the machining process, took only 20% of the time of manual drilling, and improved quality because feed rate and position were consistent for every part.

‘The new CNC router substantially improved our manufacturing operations by drilling holes in PVC faster and with a much higher level of consistency,’ Moulton said.

D L Manufacturing, North Syracuse, New York, USA, produces products for the warehouse and loading dock industries.

The company’s MxV knockout dock door features durable polymer top and bottom panel brush seals that make the entire perimeter of the door weather-tight yet allow the door to be knocked out without damage if, for example, it should be struck by a forklift.

Corrective slots are built into the MxV’s track to form a self-correcting design that allows the doors to be reset into position simply by opening and closing them.

The hinge is designed into the extruded the door panel.

This makes placing each panel easy and the interlocking panels snap together for smooth operation without added hinges or hardware.

Magnets hold the door down by reducing the upward biased effect of the counterweights.

An optional circular porthole is weather-tight and offers the added safety of visible verification of truck activity.

* Manual drilling was slow and difficult - the doors are made from PVC panels and require holes to mount the end cap and a slotted hole for the hinge pin that holds the panels together.

Eight to ten panels are used in each door and each panel has eight holes that need to be drilled.

Doors that are ordered with the optional porthole also require the hole to be cut out.

A lock was not offered until the product was produced on the CNC router, sparing the company from what would have been a very difficult manual machining operation.

The lock required a cavity to be made and holes to be drilled with precise locations.

The company did not offer the lock set option because this machining operation was too difficult to produce by hand.

Moulton felt that CNC would solve these problems by ensuring consistency in accuracy for hole position locations.

He looked at CNC machining centers of a size that could handle the company’s largest panels, which range up to ten feet long.

He discovered that the least expensive machines in this class cost in the neighborhood of US$100,000, which was more than he could justify for this operation.

‘These were very heavy machines with a cast iron base that were primarily designed for cutting metals,’ Moulton said.

‘I felt that they were a lot more than what we needed for our doors so I looked around for a less expensive alternative.

I discovered the Techno LC CNC router, which turned out to be a very good fit.

This router provides the accuracy, speed and ease of programming and operation we were looking for.

The machine was designed specifically for the materials we work with as well as wood, polymers, and nonferrous metals.

Best of all, we paid less than US$30,000 for the machine, fully equipped with software, automatic toolchanger, and a special extension on the table to support our extra long parts.’ * Accuracy and reliability in a low-cost machine - the LC Series from Techno-Isel, New Hyde Park, New York, provides a number of critical features that allow it to deliver accuracy and long-term reliability of a level that has previously only been available from machines at a much higher cost.

Techno’s LC Series machine is equipped with ball screws on all three axes with closed loop servo motor drives.

This high tech superior drive system provides smooth playfree accurate motion, which requires no adjustments and minimal maintenance.

Despite the fact that this was the company’s first piece of CNC equipment, setting up the machine to produce the panels was not difficult.

Moulton used BobCAD computer aided design software to define the geometry of the panels.

The software produced the G-code required to run the CNC router.

Moulton defined the program to produce a series of four panels with each setup.

The machine drills four holes in one side of all four of the panels.

Then the operator rotates the panels and the machine cuts the holes on the other side.

The machine also routes out the irregular cavity required for the lock and drills the mounting holes.

The router also cuts out the optional porthole when needed.

The program includes instructions to change tools automatically when needed to perform these operations.

In addition the LC Series machine interface is very easy to use.

* Improvements in productivity and accuracy - ‘The CNC router has substantially improved our machining operations,’ Moulton said.

‘The time required to perform the drilling operations has been reduced from ten minutes to two minutes for each part.

The time required to machine the porthole has been reduced by a similar proportion.

The CNC router also accurately produces the lock cavity, which would have been difficult or impossible to machine manually.

The accuracy of the holes has been substantially increased.

The CNC router cuts with the same feed rate and puts holes in the same location every time.

This saves time in our assembly operation and improves the appearance of our product.’ The machine comes fully assembled and includes Techno’s Windows-based CNC G-code interface with free lifetime software upgrades.

The machine is available in three sizes, with work envelopes of 30 by 24in, 48 by 48in and 48 by 96in.

Each of these models provides a repeatability of 0.001in, a resolution of 0.0002in and a maximum speed of 250in/min.

A wide range of optional equipment is offered including a laser scanning module, CNC lathe attachment, Porter Cable router, vacuum blower, and fourth axis rotary table.

The 4ft x 8ft model base starting price is US$16,995.

Moulton also said the CNC router has proven to be an easy to use and virtually trouble-free addition to the company’s equipment list.

‘We are a small company and this is the first CNC machine that I have worked with.

Despite that fact, I found the Techno LC to be straight forward and easy to use.

I had our programs completed and the machine in production in less than three weeks from the time it was delivered.

The machine has done its job day in day out without requiring any maintenance.

I would recommend it to any other manufacturing company looking for an inexpensive and trouble-free method to improve productivity and quality in machining plastic and wood parts.

I have just received my second machine to process door track.’

http://www.manufacturingtalk.com/news/toi/toi111.html

A CNC router machine moves and cuts in three directions at once. The X-axis runs front to back and is the longest distance the machine can travel. The Y-axis goes from left to right, and the Z-axis is up and down. Since the CNC router can move in several directions at once, it can create patterns and shapes quickly.

Where it begins

The work starts with the attached computer that controls the motion, design, and cutting. You can either work directly at this controller, or work from your desktop and transfer the design when it’s ready. You can also set up the CNC router machine to work on a new design while it is in use.

The computer aided design (CAD) software is the focal point for every move your CNC router machine will make. Operating on a Windows-based interface, the CAD software helps you design your product. It will then output instructions, called tool path files, onto the PC controller to tell the router exactly what to do. The controller sends direction signals to the motor drivers and the router moves in the requisite directions to create your finished design.

Most CAD software is compatible with most CNC router machines. You can purchase software directly from your CNC router vendor or buy it separately.

Making the cut

Once the design is ready, you place the material on the mechanical base – the main table of the machine. You can manually hold down the material away from the cutting tools, or use a vacuum pump to prepare your material for routing. A dust hood or hose collects chips and debris at the point of routing. In addition to keeping your work area clean, they also prevent harmful materials from getting into the air, such as explosive aluminum dust.

The motors control the very precise motion of the CNC router machine’s drive system. This moves the axes back and forth on a separate device called a gantry to make cuts in different directions. The drive system determines the quality and accuracy of the cut and therefore how well parts fit together later.

Spindles provide the cutting power by spinning the smallest but most critical part of the machine: the CNC router bits. These CNC router bits are similar to drill bits and come in a wide variety of sizes and types.

Safety considerations

CNC routers have guards that protect your hands. This allows you to reduce the risk of injury when feeding material into the machine.

Emergency stops are mounted strategically around the machine. The operator can hit these at any time to completely shut the router down. Operators should also use heavy-duty gloves when handling the machine to protect themselves from any jagged edges and sharp router bits. Since the machine is quite loud, they should also wear ear protection.

http://www.cnc-info.blogspot.com/

Some technology allowed humans to use machines and program codes to do things that had been done manually. CNC is one of these technologies.

CNC routers have been of great help in many fields (signage- making, 3D moldings and furniture, just to name a few). In that regard, it would be very helpful for its users to know how to get the best deal and quality on their next purchase of CNC routers.

Here are some tips on how you can get the best CNC routers.

1. Buying CNC routers from a manufacturer would be more advisable than buying from distributors.

Buying from a manufacturer will give consumers the following advantages -

- The guarantee that the sales representative knows a lot about the product. Who would know the product better than the manufacturers themselves?

- Consumers can buy the items at a cheaper price too, since there are no third parties or go- betweens involved in the transaction.

Just make sure that you know the nearest service center of the company so that you know where to go to in case you need follow- up services from them.

2. Visit multiple stores to try the different CNC machines.

- It would be advisable that you have materials that you can work on when you try the machines. Bring these materials home to see that of the products can give the quality of workmanship that you are looking for.

- Also, it would be advantageous if you can also check the machines ease of usage and your comfort while you are using the product. These things will help a lot in deciding that router you will use.

3. It is advisable to buy a new CNC router.

New CNC routers are more efficient, and the quality of work can be assured. Of course, not all circumstances would allow businesses the endeavors of having a new CNC router.

In case you would buy used CNC routers, here are the things that you need to look for -

- At least one year warranty from the seller just as an assurance that you would not have to shoulder repair expenses within that period.

- Make sure that all of the upgrades necessary for the machine have been done.

- Ask if it would be possible for repairs to be done after a year and ask how much it would cost.

4. Consult your vendor regarding your CNC router needs so that you will not buy something less than what you are expecting or something more that can add up to your expenses.

5. Test the durability and the reliability of the CNC routers.

These are the two qualities that a CNC router must be able to meet. All the parts of the router should be sturdy enough to carry on the heavy work. Minimal vibrations must be felt during operations, and the cuts must be precise, accurate and smooth. You must know these things before buying the product, and not after you purchase it.

6. Get the software that is easy to learn, manipulate, program and fix during errors.

When using CNC routers, operators will be dealing with programs and codes that tell the machine what to do. That is why it is a basic requirement for the operators to be accustomed to the software that he is using. Most of these things he will learn during trainings and product testing.

7. Consider workspace and the jobs to be done in buying CNC routers.

Materials that CNC routers are working on vary in characteristics such as hardness. Your CNC routers may do the job easily on this product, will have a hard time working on another. These things must be taken into consideration when buying CNC routers.

Also, workspace is another issue. Make sure that your workspace can accommodate the machine that you will be buying.

8. Price is relevant to the CNC router and the future profit that it can bring you.

Do not get a CNC router just because it is cheap. Think long term.

Your CNC router is the key in making the most out of your business. So give it your best shot to follow these tips to get the best CNC router to cater to your needs!

http://articlehub.com/Computers_And_Internet/CNC-Router-Buying-Guide.html

Techno’s Tabletop CNC Router

Techno adds a new size to its LC Series CNC router product offering. The new size machine, the Model 3024 LC Series Tabletop CNC Router, has a work envelope of 30″ x 24″ x 5″ and is equipped with Techno’s closed-loop servo-motor drives. In addition, it comes complete with Techno’s Windows-based Gcode Interface that is upgradable free for the life of the machine. It can be equipped with a variety of spindles and accessories, including automatic tool changer, laser scanner, 4th axis rotary table, and a variety of clamps.

Maxym CNC Router

Maxym Technologies offers a three-axis CNC machine that is low cost and easy to use. The machine allows for direct machine programming with our own CAD/CAM package. The machine work sizes range from 2′ x 2′ to 4′ x 5′ with an optional automatic tool changer available.

Shop Sabre CNC routers

From the base model with a 48″x 38″ cutting area, to the largest with an 84″ x 147″ cutting area, Shop Sabre offers standard on all models, steel welded construction, THK linear rails, THK ball screws on X,Y and Z Axis, and high power stepper motors. In addition, a full line of professional options are available. Whether you’re a hobbyist and want the highest quality machine, or a large production facility running 16 hours a day. Shop Sabre has a model to fit your needs.

CMS ARES-PX5

CMS announces its new ARES-PX5 CNC machining center. It provides full 5-axis interpolation for chair parts, carving, entry doors, stair volute up-easing combinations and modeling. The work areas span from 5′ x 12′ x 4′ to 8.5′ x 19′ x 4′ with multiple zone configurations for pendular production or single-work area production. In addition, the 16-hp, 5-axis liquid-cooled spindles have fast tool changing capability.

C.R. Onsrud CNC routers, inverted routers, and routing accessories

C.R. Onsrud, Inc. offers a broad line of CNC products including 20 models of standard CNC Routers. C.R. Onsrud features Cast Bridge, Twin Table, and Moving Gantry designs. All include 12-position tool changers, high-grade standard components, and 24/7 tech-support. A full menu of custom options includes multispindle drills, multiple aggregate stations, C-axis and 5-axis spindles.

New Hendrick CNC Router Model 20ZXG

A new heavy structure design and improved CNC control software gives the Hendrick 20ZXG CNC router high speed accurate machining capabilities. Feed rates up to 2,000 in. per minute and positioning accuracy of +/- 0.002 in. with repetitive accuracy of +/- 0.0008 in. are obtained. The moving gantry design utilizes AC servo drives, linear ways and ball screws on all axes for smooth and accurate movement. Up to 10-hp high frequency router spindles with automatic tool changing capability are available. Other features include PC controller with built in CAD/CAM software, vacuum table machined for zoning and pod fixturing, low vacuum pressure safety cutoff and air blast tool cooling. The machine is also available in many different table sizes.

Multicam 5000 Series

MultiCam introduces the new 5000 Series CNC router line. The 5000 Series is stronger, faster and heavier than its predecessor, the MG Series. Loaded with many standard features, the all-steel, moving-gantry design allows machining of large parts while maintaining a mid-sized, space-saving footprint. The new MultiCam 5000 Series is available in over 40 standard machine sizes from 50″ x 50″ to 120″ x 362″.

Fulltech Centek machining center

The Fulltech Centek 5121-A machining center, now distributed by Multiax, is ideal for nested-based manufacturing and is specially configured for efficient and versatile quick change to vacuum pod applications. The Centek 5121-A has many options for milling, sawing and boring features, high performance and stable closed gantry, and uses state-of-the-art electrical and mechanical components.

CNT Motion Systems CNC Routers

CNT Motion Systems offers full-size, USA-built, CNC Routers for nested-based manufacturing of plastics, hardwoods, solid surface and non-ferrous metals. CNT Motion’s heavy-duty, affordable technology is also being applied to custom configurations for a variety of unique applications, including over-sized materials processing, 3-D multi-axis configurations or unusual material fixturing.

Bladerunner CNC

Bladerunner CNC introduces its Series 03, a production-grade CNC router aimed at those previously deterred from using CNC technology. Its three simultaneous axes movements make it ideal for a wide variety of woodworking applications including cabinet, sign, furniture and clock making. It integrates the design and cutting software into a unified, easy-to-learn computer package that ensures users are up and running in a matter of hours. Bladerunner Series 03 CNC router is available in three standard sizes: 4 by 4 ft. by 12 in.; 4 by 8 ft. by 12 in.; and 5 by 10 ft. by 12 in.

Komo SOLUTION traveling gantry model

Komo Machine’s SOLUTION CNC Machining Center line was designed for the small-to-medium sized CNC router market. The Solution Series has been developed specifically for the cost-conscious yet demanding customer who expects the utmost in technical quality and reliability. Featuring a moving gantry configuration with table sizes available to 50′ in the X axis, it utilizes the exclusive Komo-GE Fanuc Panel “i” control with HVI servo system and integrated Windows® based PC.

Holz-Her Conquest 250

The Conquest 250 CNC router from Holz-Her features Star Brand linear guides in all axes, brushless drive motors and an eight-position tool changer mounted on the head. The boring block on the Conquest 250 is equipped with a 49″ x 98″ table with the ability to separate into two work zones.

FlexiCAM CNC Routers

FlexiCAM is a German manufacturer of CNC routers and offers routing solutions for the Woodworking Industry. FlexiCAM systems are amazingly versatile, rugged and fast, allowing for quick and accurate production runs. Along with the range of standard products, FlexiCAM also provides customized machines for user specific applications.

Omnitech’s SELEXX/PRIMO

Omnitech Systems introduces it’s latest edition to the SELEXX series of CNC Routers, the SELEXX/PRIMO. With a table size of 5′x 20′ the machine offers dual vacuum zones (5′x 10′) which can be used for both nested-base manufacturing and individual parts processing, alternating both zones. The machine is equipped with a FANUC controller, the very reliable ANDI 10-hp spindle, eight-position automatic tool-changer, plus vertical and horizontal drills.

EZ CNC ‘turn key’ CNC routers

EZ CNC offers a complete line of affordable “turn key”, easy to use CNC routers featuring high power motors; industrial drives; hardened rails; and recirculating bearings for fast, smooth, precise movement. Together with easy-to-use CAM software, it provides a cutting system that is rugged enough for a production shop and easy for the new CNC users to master.

Thermwood CNC Controls

Thermwood now offers part nesting as a standard feature of its CNC control. It accepts DXF files from any major CAD or design software and can nest parts from different software in the same job. Control nesting offers several advantages. You can easily nest on partial sheets left from previous jobs. The control prints a bar code label for these when they are run, which makes it easy to identify them for use in a new job. Also, you can easily nest around surface defects found when running a job. These features reduce scrap and improve yield while eliminating numerous trips to the office to create modified nests.

Accu-Router 5th- generation automated conveyor system design

Accu-Router’s fifth-generation automated conveyor system design has two high-velocity machine cells that are served with a common conveyor system. This system has new load/unload approach with each Accu-Router. A powered queuing table and exit table will work in concert with pop-up powered table rollers to do the load and unload sequence in one move. There will be a common stacker station with multiple bunk access, automatic loading to first available queuing table beside each machine, a 24-in. long sorting conveyor where cell labor will be positioned, and a common return conveyor with the bleeder boards. This system will maximize output in either a stacked or single panel cutting environment.

Morbidelli Author 430 SNB CNC Machining Center

SCM Group USA offers the new Morbidelli Author 430 SNB CNC Machining Center. The Author 430 SNB is available in a variety of table sizes 4′ x 10′ up to 5′ x 22′ and has an optional rake system for increased production. The Author 430 SNB features a 24-spindle drilling head, 15-hp HSK F63 liquid-cooled router and 10-position rapid tool changer. The Author 430 SNB has a user-friendly interface operated by a Windows XP platform, standard office PC and is supplied with CAD/CAM software compatible with all major design software packages.

Homag’s BOF 712

Homag’s new BOF 712 fixed-gantry processing center, available from Stiles Machinery Inc., features advanced CNC routing technology; single or dual work zones and Independent Process Optimization (IPO) logic. The BOF 712’s two worktables can act as one to accommodate larger workpieces or operate independently of each other. Two 14.5-kW high-speed router spindles work either in tandem or completely independent of each other. Each working unit is standard with a dynamic 12-tool ATC unit and 12-spindle drilling unit. A 40-hp liquid-ring vacuum pump is also standard. A variety of matrix and pod table fixturing options is available.

Northwood NW 510 CS-RH

The Northwood NW 510 CS-RH is specifically designed for the upholstery furniture and boating industry. The machine has an integrated “Quad” roller hold-down system that consists of four quick ply rubber/fiber plicord covered steel rollers. The rollers are operated via the CNC controller to control up and down positioning. The roller system allows for material to be stacked up to 2 in. high and machined. The machine is configured with programmable spindle center spacing.

Busellato Jet 200 RT CNC router

Busellato’s JET 200 RT CNC Routers are a solution for nesting cabinet parts as well as machining individual components on raised pods. The Jet 200 features the automatic unload device with integrated dust extraction that gives you a total load and unload cycle time of under 30 seconds thus greatly increasing the number of sheets that can be processed in a shift. The drill head has 19 vertical and eight horizontal spindles, 16-hp HSK electrospindle, 15-position rotary tool changer and grooving saw. The machine can be equipped with elevated pods that allow profile and horizontal machining, allowing the machine to work as a traditional machining center as well as a nested solution.

http://www.wooddigest.com/article/article.jsp?id=337&siteSection=0

A computer numerical control (CNC) router provides a very economical method of producing prototypes of counter display units. The displays are injection molded with molds that cost from $50,000 to $100,000 so prototypes must be built first to verify each design. The physical prototype is used to validate critical aspects of the geometry and obtain customer approval on the design geometry. Machining centers are used to build many of the prototypes, especially those with 3D contours. On the other hand, the CNC router, which costs much less than a machining center, very efficiently produces prototypes that require only 2 ½ D machining. The router is also used to machine fixtures used to build wire display components.

Alliance Display and Packaging is a leading producer of point-of purchase displays, particularly PDQ units used to display cosmetics in department stores. These counter-top display units are typically 30 inches wide, 15 inches deep, and up to 4 inches high. The display units are injection molded from styrene or polycarbonate. The injection molding process requires the construction of a large and complex mold prior to producing even a single piece. “If we were to build a mold to create prototypes, and we discovered a mistake in the design or the customer wanted to make a change, there would be a good chance that we would have to throw away the mold,” said Mitch Nelson, Mold Shop Manager for Alliance Display.

Need for a physical prototype
While the latest computer modeling tools provide a very realistic view of a proposed design, there are often very important aspects of the design that go beyond visual appearance. One reason is that rendering software alone is unable to perfectly represent the way that an object appears under certain lighting conditions, certain angles or any combination of those two. The computer comes close, but close isn’t good enough when you are about to make a decision to invest money to bring a new product to market.

The simple fact is, that nothing beats the reality of a three-dimensional model sitting in front of you. With a 3-D model you can see, touch and feel the subtle changes in a curve or line, or the way a door handle transitions into the door panel. You can walk around and look from any angle at the way the light reflects off a given surface. This holds true for any product whose appearance is very critical, not just point of purchase displays. Even the Art Center College of Design in Pasadena advocates the use of physical models for critical aesthetic decisions.

Building a prototype also forces the designer to resolve issues that would be too easy to gloss over in a computer model. There are hundreds of issues that usually don’t begin to get addressed until the first prototype is built. Just exactly how do pieces fit together? Does it work the way it is intended to? How does the user hold the product? Exactly how will it be used? How does it fit in with other products that it is to be used with? Does it have the right feel? How does it look in the environment in which it will actually be used? How do the products potential purchasers react to it? You aren’t likely to get an answer to any of these questions or many others until the first prototype is built.

Machining center provides costly approach
Alliance Display uses machining centers to produce prototypes out of styrene or acrylic sheet. The machining center is required for making prototypes whose geometry is very complex. “About a decade ago the company purchased a CNC router designed for machining plastic and wood for about $20,000,” Nelson said. “This machine cost much less than either a machining center or a stereolithography machine but performed just as well in machining plastic prototypes. But over time, the software became outdated. We stopped using the machine.”

Upgrading a CNC router provides solution
Recently, Nelson wondered whether it would be possible to upgrade the machine, which had performed very well. He contacted its manufacturer, Techno-Isel, New Hyde Park, New York, and discovered that the machine could be retrofitted to the latest LC series model electronics for a minimal cost. The retrofitting process included changing the axis motors from stepper to servo motors, a new control system, vacuum table, and new software. This new retrofit not only brought the machine up to current technology, but the machine ran faster and smoother then ever before. A closed loop servo control system provides constant position feedback, higher power, and smooth continuous motion that eliminates the possibility of losing position in the middle of a part. A big plus was the new Windows based GCODE interface. The interface was extremely easy for the operators to learn to use.

Nelson had also considered purchasing a new machine such as Techno’s LC Series which is constructed on a heavy steel ground stress relieved base, and includes a heavy duty aluminum T-slot table and ball screws on all three axes with closed loop servo controls. Because the frame is a single welded piece, there is no chance for it to get out of square or require alignment. The machine comes fully assembled and includes Techno’s Windows-based CNC G-code interface with free lifetime software upgrades.

The machine is available in five sizes, with work envelopes of 30 by 24 inches, 50 by 48 inches, 50 by 96 inches, 59 by 120, and 78 by 120. Each of these models provides a repeatability of 0.001 inches, a resolution of 0.0002 inches and a maximum speed of 250 inches per minutes. A wide range of optional equipment is offered including a laser scanning module, variety of spindle options, vacuum pumps, and fourth axis rotary table to name a few. This entire series of machine are very reasonably priced, for example the 4-foot by 8-foot model sells for $16,995 new. “Based on the advice from Techno stating that my machines mechanics were in perfect condition, I made the decision to simply upgrade the controls, and put off the purchase for a new Techno router until I require a larger work area,” Nelson said. “Thanks to Techno my upgrade was simple, quick, and most importantly cost effective.”

The new prototyping process
Alliance Display uses Strata 3D rendering software to produce their initial design concepts. The renderings produced with this software are shown to customers for approval. When the customer approves the rendering, the company then moves into the engineering stage and produces a solid model of the design using SolidWorks computer aided design software. The solid model is then moved into the Mastercam CNC programming environment where Nelson generates the toolpaths needed to produce the part on the router.

The operator simply mounts a sheet of styrene or acrylic on the vacuum table, calls up the appropriate program, and hits the start button. He then walks away while the router produces the parts. It takes between one hour and 30 hours to produce the display on the router. The finished pieces are then decorated with paint and pressure sensitive labels. The longer times are for complicated displays that might consist of as many as 50 components. The physical model provides a truer picture of the appearance of the display and also gives engineers a chance to resolve details that are difficult to verify on the computer such as snap features and interlocking. When engineering and the customer have signed off on the prototype, then Alliance Display can confidently begin producing the injection mold, working with the same geometry that was used to produce the prototype.

“The low cost of the CNC router means that we can produce prototypes very efficiently at Alliance Display,” Nelson concluded. The retrofit has breathed new life into a 10-year-old machine at a very low cost. The machine has proven to be very reliable and easy to use. In approximately one year of operation since it was retrofitted the machine has performed without any problems. People that have never seen the machine before are able to operate it at full efficiency within an hour or two. The result is that we can provide our customers with beautiful prototypes at a low cost.”

http://www.plasticsnet.com/content/news/article

With absolute accuracy of 0.0001 in. and relative accuracy of 0.0005 in., OmniRaptor(TM) meets stringent demands of dynamic manufacturing environment. Unit includes 2 kW, water-chilled, 60,000 rpm spindle; 5/6 in. dia collet; and 15-tool station-style rack. Ethanol-Mist Coolant System(TM) eliminates secondary processes such as deburring or degreasing. Microsoft[R] Windows[R]-based controller works with virtually any CAD/CAM software and offers Ethernet networking capability.

Milford, NH, March 25, 2005 - The OmniRaptor(TM) is the latest CNC router to be added to Datron’s Raptor Class of machining centers. With absolute accuracy of 0.0001″ and relative accuracy of 0.0005″, The OmniRaptor(TM) is designed to meet the stringent demands of a dynamic manufacturing environment. Feed rates of up to 800 ipm produce optimized cycle times making this machine ideal for high-volume production schedules. A steel bridge reinforced with polymer concrete provides superior stability and support for heavier spindles. The 2kwatt (2-3/4 hp), water-chilled 60,000-RPM spindle has the torque to handle the most challenging workpieces, multiple shift production or high material removal. The 5/6″ diameter collet and heavy-duty design can handle large or continuous workloads and optimize cycle times. A standard 15-tool “station-style” rack with tool-length sensor can be upgraded to an optional 30-tool station for added capacity. Faster feed rates, stabilized gantry, integrated pneumatically covered tool magazine, LCD flat-panel display, polycarbonate side windows and a removable chip cart on wheels are just a few extra features that distinguish the OmniRaptor from other Datron models.

The OmniRaptor’s vibration-dampening concrete polymer machine table equipped with a built-in 15-tool, Automatic Tool Management System(TM) can be ordered with a 36″ knock-out as a free option. The OnmiRaptor’s 60,000-RPM spindle produces low force and superior quality when tooling 0.250″ and under. An integrated Ethanol-Mist Coolant System(TM) provides for superb surface finishes and eliminates secondary processes like de-burring or de-greasing to further improve cycle times. Datron’s Microsoft[R] Windows[R]-based controller works with virtually any CAD/CAM software and offers Ethernet networking capability, as well as remote monitoring and control, allowing the machine to seamlessly integrate into any manufacturing environment.

The OmniRaptor can be set up to accommodate Datron’s proprietary Quick-Pallets(TM) workholding technology, which provides manufacturers with reduced job setup and job changeover times. This lightweight, manual pallet changer facilitates batch machining and “lights-out” production rather than single-part production. To insure X, Y, Z location repeatability, the pallets are registered using a beveled-boss in cavity system. When placing the pallet on the machine bed, it will be located in exactly the same spot every time. A standard feature, vacuum pump holds the pallet in place during machining operations. Changing a pallet requires no tooling or clamping, reducing setup time from an average of 30 minutes to 30 seconds - making the OmniRaptor ideal for frequent or interrupted job changes.

Other available options include a Z-Correction Probe(TM) that measures surface irregularities and compensates for them dynamically, a 3D Probe Extension that enables Z-Correction Probe to function in 3D (X, Y and Z), a Renishaw TP20 Probe for complex part measurement, 4th and 5th Rotary Axes (servo-controlled rotary axes), Windows Control (offline version) control software that enables programming and program testing from remote PC, Vacumate(TM) and Quick-Pallets(TM) workholding for quick setup and a Digital I/O that provides 8 outputs from the CNC control.

For more information on Datron’s EcoRaptor, contact Robert Murphy at Datron Dynamics, Inc., 454 Route 13, Milford, NH 03055; toll-free 888-262-2833; website www.DatronDynamics.com; e-mail: info@datrondynamics.com.

About Datron: Datron Dynamics is the North American distributor for Datron Electronic, a German technology firm established in 1969 that has become a leader in the design and development of CNC machining and dispensing systems. Founded in 1996 by President, Walter Schnecker, Ph.D. and Vice President, William King, Datron Dynamics is differentiated in the marketplace by its focus on high-speed machining with micro tooling. Datron machines feature 60,000-RPM spindles that produce low force, feed rates of up to 1000″/minute and superior quality when tooling 0.250″ and under. An Ethanol-Mist Coolant System(TM) provides superb surface finishes and eliminates secondary processes like de-burring and de-greasing while being environmentally friendly. Other features such as the Z-Correction Probe(TM), Automatic Tool Management System(TM) and their proprietary Quick-Pallets(TM) and Vacumate(TM) workholding systems enable batch machining and “lights-out” production. These distinctions have resulted in over 1,000 installations worldwide within industries requiring superior production of EDM electrodes, hot stamping and embossing dies, 3D mold making, rapid prototyping, 3D precision engraving, front panels and the production of automotive and aerospace parts.