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Step 3: Prototyping

To get a feel for my toolpaths, I ran a prototype in pink insulation foam.  Foam is great for testing because it is cheap, readily available, and easily machinable.  I modified the feeds and speeds to go for the maximum that the machine was capable of.  This meant that I had a complete mockup in my hand in only 30 minutes.  When machining foam, it is critical to vacuum during the process. I ran without coolant and held the shop vac next to the cutter for the entire operation time.  

There are two prototypes here.  The first one that I ran was done with a .050" step down, and is the second set of photos.  The second one, which was the same code as the final metal version, was run with a 3/16" step down.  
This is great! I did a whole series as an undergrad with the <em>Memento mori</em> theme, I'm a sucker for such things. Well done!
<p>4 or 5 Axis CNC Router </p>
<p>Yes! I would like to see the codes too! :-)</p>
looks pretty good!! i have featurecam but not in 3d, can you send me cnc text file? <br> <br>thanks
could you please add the (STEP) file as well.
hi, would you be able to upload an (STL) file as this would be very usefull, thanks.
It will be nice if you can put a STEP, IGES or Parasolid files so every CAD/CAM system can open your model and not only Solid Work. <br>For the rest, good job on the model and the fabrication.
I've added an IGES file of the model; If you're still unable to open it, let me know, and I can try something else.
Yeah, I can't open whatever kind of file that is in Mastercam.
Unfortunately, I don't have access to CAMworks right now, so I can't mess around with its data formatting. I will have a more accessible CAD file up soon, though. Thanks for reading and commenting!
i try something like this whenever i can.....but im more of a trail and error kind of man, sooooooo no computer for me.
Sweet dude! I might have to try this. Nice guide!

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Bio: I'm a first year product design student at Hampshire College. I know how to make lots of things, and I can usually figure things ... More »
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