Okay, there’s the BlockSCAD XML:
Box - plywood - kerfed - v3.zip (33.2 KB)
Next up will be exporting it to OpenSCAD and setting up the Customizer options and flattening things to make DXFs.
Okay, there’s the BlockSCAD XML:
Box - plywood - kerfed - v3.zip (33.2 KB)
Next up will be exporting it to OpenSCAD and setting up the Customizer options and flattening things to make DXFs.
Trying to wrap my mind around DXFs (since that’s the 2D export from OpenSCAD)— please confirm/refute my thoughts on this:
The only work-around I’m seeing here is multiple exports — the traditional top/front/side views aren’t supported by a wizard in Carbide Create or MeshCAM (does the latter support 3D DXFs? If so, how are they made?) The only workable export I’m seeing from OpenSCAD which would work with Carbide Create would be a succession of top views, one for each sort of cut which would then have to be stacked in register in a Carbide Create file and appropriate toolpaths (and/or 3D modeling in Pro mode) assigned.
Is there anything I’m missing or not understanding in the above? Is there some better solution (other than using Autodesk Fusion 360)?
Okay, working through the export. For most parts it’s pretty straight-forward. We add three variables:
Endmill_Diameter = 6.35;
cuttingwidth = ceil(Endmill_Diameter * 1.1);
tcw = cuttingwidth * 2;
and then wrap each exported part thus:
projection(){
difference(){
translate([-cuttingwidth, -cuttingwidth, 0]){cube([Box_Depth + tcw, bottomheight + tcw, 0.001], center=false);};
translate([0, 0, -0.001]){makeside();};};};
which results in a part suited to exporting as a DXF:
Next up is doing that for each part.
For parts which have V cuts the V cuts are output in addition to the actual part outline surrounded by a rectangle of the same size:
this allows them to be imported into Carbide Create:
and the two cuts dragged into register:
and appropriate toolpaths assigned:
Import all of the parts into a file and arrange them so that they can be cut out:
then begin assigning toolpaths.
For elements which do not match an available endmill use 3D modeling rather than an endmill for a V carving:
This then allows cutting the arbitrary angle:
along with the kerfs as an Advanced V carve:
Add toolpaths to cut out the perimeter and leave tabs:
Part removal was easier than expected, and bending worked well for the top curve. The 90 degree bend seemed to work well, but not as much success with the sharper bend on the top strap — 3D modeling that didn’t work as well as expected, will have to check the settings.
The 90 degree is likely just too much stretching for the fibers in the remaining layer. You’ll need a lot more of a smaller kerf, to make the bend distribute the tension along the remaining layer.
Agreed. I think I’ll skip the 3D modeling and instead just do a series of 30 degree V carvings. Modern adhesives would probably make it work, but I want something stronger and with less post-processing.
This is a venerable woodworking technique, and came across this fascinating article:
First try at the 90 degree bend with just as many 15 degree V grooves didn’t quite make the bend:
adding more and cutting again — will probably go to vertical front/back and change the bottom to have flaps on all sides and flip it over
Rather than iterate with large chunks of plywood which would then have to be repurposed, have decided to do what I ought to have done to begin with: a series of systematic test cuts.
Since I have a Starrett protractor head which has a half-length of 2", will use 4" sections.
The successful bend above used 0.0082" in-between each kerf:
so we’ll make a series of parts thusly, labeling each as to the number of grooves, then glue them up and measure them.
So, we make a test file:
Next up is toolpaths, then cutting, then cleaning everything up and glueup, then measurement.
I guess I’m just too busy with my own projects to even think about testing that way. Will, you must be possessed! +1
Made a file for making test files:
https://www.blockscad3d.com/community/projects/961603
Next up is exporting that to OpenSCAD, hooking up the customization, and adding the command to flatten out the DXF export option so one can actually export a DXF — then I can try cutting a file again.
Updated to make two different sorts of test cuts (Number or Spacing):
After exporting to OpenSCAD, it’s the same drill: