CNC Foam Cutter

CNC Foam Cutter Build Pictorial

DAY 1

The plans call for building the right and left X axis structure. A little on axis, normally the X axis would be considered as left & right movements, the Y axis would be considered forward & backward movements and the Z axis would be considered up & down movement. However, with this foam cutter design the X axis is a variable because the distance of the two "tower" structures can be position by the user. And what we are actually building is the Y and Z axis. Since this is my first time to build this unit and I have not run the software, I will have to find out later if the software or controller considers the Z axis to be the X axis. I know on my CNC Router, the software and controller run all 3 axis separately but again the X axis on my router is not a fixed position as it will be with this CNC Foam Cutter.

Following the plans I cut out all the pieces necessary to construct the CNC Foam Cutter. The plans were easy to follow and everything had to be cut times two since we need to build two "Tower" structures.

Here is the base for the two Y axis just after cutting them with my table saw.

The stepper motor mount of the Y axis is being assembled in the picture below. I decided to deviate from the plans and not use nails and glue to adhere the pieces together as suggested. Instead taking what construction methods I have learned from building my CNC Router I opted for drilling, tapping and bolting the pieces together. This will serve two purposes. The first, I can break the unit apart if ever needed. And second, if we decide to produce and sell these units, it would be easy to ship and allow the buyer the ability with common tools to assemble the unit.

The motor mount is almost completed.

After completing the motor mount I secured it to the Y axis base. Because we will have slide rails mounting later on the base, I decided to go head and mark the start point with a pencil line. This will make sure the rails align even if the triangle support braces are a tad too short.

Ok, both Y axis motor mounts have been secured to their base. Looks good so far.

Here is a side view of the bases.

Again, instead of using nails and glue, I opted for bolts. This was something not mentioned in the plans but will be a standard in our construction through out.

I through this picture in to get an idea of the size when compared to my CNC Router that I am still constructing. As you can see the base is quite long and should accommodate for cutting large wing chorded foam wings. I can't wait.

Stay tune for more pictures as our progress continues on our CNC Foam Cutter build.

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