So I have never made or used a texture before with CNC. I learned a ton of valuable info from working on this including important stuff like how small I can go and how much is too much lol.
So I always admired the C3D logo, I prefer symmetrical construction and have done detailed Hexagonal structures before for video games.
Game design limitations included how many surfaces would be visible in one view, and you had to get creative and put up blocking walls and other various methods to reduce visible surfaces, they did not have the haze effect back then.
I was building the secret levels for a PC game called Malice which was a add on for the game Quake back in 97, and I built a hexagonal hospital that was way over the limit on visible surfaces but it was so cool, I asked John Carmack whom I had met previously, to help me out and raise the surface limit in the next version of the Quake game engine. To my surprise he said yes and gave me a beta version to work with until the game was published then released the updated version to the public. I was able to finish the level without shredding all the surfaces and in the finished game my hospital level had the most detail and surface count published to date and the game won awards and was a success!
Flash forward 23 years later, still did not learn my lesson and here I am building stuff that is way over the limit and I have no business trying to make lol, and I had no idea what I was getting into when I hit the generate tool path button.
I used 1 inch hexagons with the logo inside and some spherical additions. The plan was to cut it out with MDF first and then if everything went right, go on to Oak. I wanted a cool 3d effect and decided to play around with some sketches to compliment the design of the texture, and do a overlay trace.
So I started with a Carbide 3d tribute plaque with 7 of the textures in the center, with the intention of engraving it after it was done, and then designed a second simple platter with 64 hexagons on the base.
After attempting to generate both on one machine, a few hours went by and it was making literally no progress, I ended up splitting them up and starting over, generating one set of tool paths on my main computer and one on a different machine that my son in law downloaded fusion to.
To my dismay lol, the tribute plaque took 3 days to generate the tool paths on a i9-7900 with 32 gigs of ram. The larger platter is still going 5+ days later on a i7 with 24 gigs, and is halfway through the 3rd tool path out of 7. Legend has it, it will still be generating tool paths by the time the voting is done ha ha, but I am going to just let it run…
The C3D tribute plaque has over 24 hours of machine time. I really needed to turn the Shapeoko off it was running for days, so I just ended it slightly early. I still had a couple additional tool paths I wanted to run but was tired and needed to shut it down and not leave it on all night again.
The operation took so long I did not engrave the textures. The MDF is so smooth and clean I did not want to mar it up. I think it would work better trying to engrave it into hardwood but then the grain might take away from it. I could not highlight or paint the engravings in MDF and they are so small I don’t know if it would look good. After the excessive machine time I did not want to damage it with a bad trace carving.
I really do not know what to do with this MDF. I have watched tutorials on Youtube where you spray sealer on it but it requires sanding and finish work for painting and the components of the texture are so small it would ruin it if I touched it with any sand paper.
Just going to leave it raw for now…
The hexagon edges and outside spheres are .05, the divots are -.05, the center sphere is .075.
A few things I learned of note, you can not bevel a 1 mm edge. Even with a 1mm end mill. And when you are going this small you really need to have your axis’ses dialed in tight.
My Z has been coming up short and it was a huge pain to fix things afterwards on this when the tool paths take 8+ hours each to generate.
I used a ball mill successfully for the first time, I setup the outer ring so I could go inside edge to outside edge without hitting the floor and it made a perfectly smooth 1/4 rounded ring.
I had to use 1 MM end mills to clean up around the centers, and learned they do slot clearing on MDF no problem with a .05 step.
I also recently got 1/4 and 1/8 flat down cutting end mills that work amazing and make perfect edges.
If you download this and carve it (24+ hours lol) make sure to adjust the negative stock depth (-.05) and the negative axial stock to leave offset (-.04) that I have set to compensate for my Z issues. I can’t re do it to 0 and re-generate, it will take days.
Was thinking if anyone has experience and materials for painting or finishing raw MDF and was interested, I could ship it to you and you could finish it up and mail it off to C3D headquarters.
Good luck and can not wait to see the other entry’s!
3am issues solved, can’t share from Manufacture, have to be in Design…
Fusion 360 Public Share Link
Photos from 97: