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Step 3: Mockup

My plan was to laminate six layers of cardboard together for each panel. 40 panels x 6 layers = 240 pieces!   That's a heck of a lot of cardboard. Luckily there is almost always someone who has just moved to town and is looking to get rid of their moving boxes for free on craigslist.  I snagged a batch to make my prototype pieces.  

I cut enough pieces to lay out a 3 x 4 grid on the floor.  This would let me see if the idea was headed in the right direction.  I'd be able to tell if I liked the star pattern made by the negative space or if should reconsider the dominoes.  After spending the evening cutting out cardboard pieces with my CNC machine I came to two conclusions: 

First, there was no way I was going to have the time / patience to cut out 240 pieces.  

Second, the recycled cardboard looked kind of crappy and the design was cool enough to deserve a better material.  

1/4" plywood perhaps?
When I first built my CNC Router at home I couldn't get it going faster than 20some inches a minute either. I had acme screws and I used a computer power supply to power the stepper motors. I wasn't happy with that so I got a HobbyCNC 3 axis drive and a used Acopian power supply, of the correct voltage and amps, on ebay. The difference was amazing! I can rapid traverse at over 100 inches a minute and can cut as fast as the cutter can handle. As far as losing steps and cutting a part that doesn't resemble what you drew I found out that you have to tune your stepper motors properly. Trial and error motor tuning worked for me.
I just upgraded to a gecko G540 driver and it's a whole new world. Now my rapids are up to 75imp. The motors are running way smoother too. I'm still having some non-reproducible errors though.
Gecko drives are much better than HobbyCNC drives. I didn't know about Gecko when I built my machine and the HobbyCNC only cost me $35. I had to solder them though.
I like home interior design and creative design and would like to make proper room divider to create more private space and showing my favorate taste. Your divider seems great.
Thanks.<br>Let me know if you have any questions. <br>Love to see pics of the finished product.
Beautiful! Thanks for sharing.<br>Sunshiine
Holy cow this is GORGEOUS!! It reminds me of those Eames childrens playing cards that had slits in them so you could stack them together. Makes me wish I had a CNC!! Excellent 'able.
Just checked out the Eames cards. They are cool. I like the images too. I can't wait to see what happens when more people have access to CNC machines. We've barely scratched the surface of the potential they offer.

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Bio: I have a compulsion to make stuff, all kinds of stuff. I'm glad to be here...
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