CNC Machine Operation Steps

⚠️These usage instructions are not a substitute for the required "Learn to Use a CNC Router" class. You must take the class and complete the checkout procedure before you are permitted to use the CNC Machines. ⚠️

Safety Considerations

End mills can snap, and the CNC will toss out chips of material. Clothing, hair, and hands can get caught in the CNC's various motorized parts. Please keep the following safety guidelines in mind:

• ⚠️ Wear appropriate PPE (personal protective equipment) ⚠️
  • Safety Goggles are required
  • Ear Protection is highly recommended
  • Depending on your materials, respirator masks may be recommended
    • If you're sure you need one, wear one
    • If you're not sure you need one, wear one
    • If you're sure you don't need one, maybe still wear one - most people only get one set of lungs
  • Face shields are recommended, particularly for materials that chip a lot (e.g., softwoods like pine)
• Keep hair, clothes, and limbs away from moving and cutting parts while the machine is on
• Do not leave the CNC machine alone while it is running
• Reduce fire and other catastrophic failure risks
  • Familiarize yourself with the safety shut offs
    • The small Shapeoko can be shut off by pulling its main power supply from the outlet on the wall directly above the machine
  • Make sure the vacuum is not over-full before cutting
  • Test your toolpaths before running live
• Reduce End Mill Snap Risk
  • Make sure you have used the correct tool (bit) and tool settings
    • In Carbide Create, double check that the bit you selected is using the settings recommended by that bit's manufacturer
    • On the machine, make sure that the bit inserted into the machine matches the bit you selected in Carbide Create
  • Make sure you have inserted the bit into the machine correctly and that the shank is inserted at least 1" into the collet

Before You Start

Check & Switch Operating System

⚠️ Attempting to use either CNC machine while the computer is booted into the wrong Operating System may break the CNC machine, cause injury, or ruin your project. ⚠️

• The small CNC machine is set up in MacOS.
• The large CNC machine is set up in Windows.

To switch to the correct Operating System for the CNC machine you want to use:

1. Restart the computer
   • On Windows: Start Menu > Power > Restart
   • On MacOS: Apple Menu > Restart
2. When the computer shuts down, hold down the Alt key until the computer loads a Boot Options menu
3. Select the Operating System you need using the arrow keys, then hit Enter
   • Note: The mouse will not be usable in the Boot Options menu; you will have to use the keyboard

Computer Login Info

• Username: All Hands Active
• Password: TheNextGeneration

Check & Empty Vacuum

The vacuum manages saw dust accumulation to keep your project area (mostly) clear and to manage saw dust in the air. When it is too full, it loses suction and cannot function properly - which will make your post-cut cleanup time longer. The vacuum also uses a reusable cloth filter, and accumulated sawdust can heat up and cause damage to the vacuum or cause a fire. Checking the vacuum is a way of Being Awesome: taking responsibility for the space and the tools we use so that they remain available to the community we belong to.

To clean the vacuum:

1. Open the vacuum by pressing the blue tabs on each side of the lid inward until the lid handles pop free, then pull the lid off
2. Clean the filter:
   1. Remove the filter ring and set it aside
   2. Remove the reusable dry filter (cloth) - leave foam sleeve in place
   3. Shake debris from dry filter into garbage bin
      • Hold the filter inside the bin to reduce sawdust getting in the air and all over
   4. Replace the reusable filter back over foam sleeve
   5. Push the filter ring back into place
3. Empty the vacuum tank:
   1. Pull the vacuum hose out and check both ends for sawdust obstructions and, if hose is obstructed, shake out over garbage bin to clear.
   2. Lift the tank out of its corner and dump the contents into the garbage bin.
   3. Put the tank back in its corner and push the hose back in place.
4. Close the vacuum by replacing the lid on top of the tank and push gently until the tabs click back into place
5. Vacuum up any debris that fell on the table while cleaning

Design Your Project in Carbide Create

• The basics of designing CNC projects in Carbide Create are included in the "Learn to Use a CNC Router" class.
• Refresher tutorials and more in-depth usage tutorials can be found on the Carbide 3D Website under Resources - Design with Carbide Create.

Shapeoko 3 - Small CNC Machine

Step 1: Secure Your Stock

To secure your stock:

1. Place your stock (as best you can) on the spoilboard so that there are available grid holes near the edges of your stock.
2. Set Step Clamps in place around your stock. Thread bolts through the center holes and hand tighten the clamps into place. The bolt should be threaded into an insert that is close to the stock for more stability.
3. Use a wrench to tighten the bolts into the threaded inserts until they are secure, but not over-tightened. You should be able to loosen the bolts with a bit of pressure with the wrench, but should not be able to loosen the bolts with your fingers.
4. Check that your stock is secure by trying to wiggle it. If the piece does not wiggle, it is secure. If it wiggles, work on your clamp placement until the stock no longer moves when you try to wiggle it.

Step 2: Insert the Appropriate Bit

Bits are inserted into a collet, which is tightened by a nut, at the bottom of the router part of the CNC machine. To insert a bit:

1. Remove the magnetic vacuum brush
   • The vacuum brush will remain off until the end of #Step 4: Zero the X, Y, and Z Axes
2. Press the button that holds the router shaft in place and use your fingers to loosen the big nut at the bottom of the router enough to insert the shank of your bit
   • If you can't finger-loosen the nut, use the large black wrench
   • Only remove the nut entirely if you need to swap collet size
     • Most of AHA's bits come in both the 1/4" and 1/8" shank size and it's easier to just swap to the bit you need that has the right shank size for the collet already in the machine
3. While keeping the button pressed, insert the shank of your bit into the collet and use your finger to hold the shank in place while you finger-tighten the nut to keep the bit from sliding out
   • ⚠️ Shanks need not be inserted into the router until they bottom out, but must be inserted at least 1" into the collet. This is a safety precaution to protect both you and the machine. ⚠️
4. Still holding the button to keep the shaft from turning, use the large black wrench to tighten the nut
   • The nut should be secure but not over-tightened (you should not need excessive pressure or to yank on the wrench to loosen it again)

Step 3: Connect to & Initialize Machine with Carbide Motion

1. Switch the red switch to the on position to turn on the CNC Machine
2. Open Carbide Create on the computer and click "Connect to Cutter"
3. Click "Initialize Machine" to initiate the machine's homing sequence

Step 4: Zero the X, Y, and Z Axes

1. Once the homing sequence completes, click on "Jog" in the upper right of the Carbide Motion window
2. Use the X+ and X- buttons to move the router left and right until you reach your desired zero X position
3. Use the Y+ and Y- buttons to move the router forward and backward until you reach your desired zero Y position
4. Use the Z+ and Z- buttons to move the router up and down until your reach your desired Z position
5. Use the Increment+ and Increment- buttons to set how fast the router moves while zeroing
6. When satisfied with the zero positions you have set, click on "Set Zero" and then you can either set each axis individually, or use "Zero All"
7. Don't forget the vacuum brush! Move the router back up using the Z+ button until you can place the vacuum brush back on the router
   • You do not need to re-zero Z after you put the vacuum brush back in place. Carbide Motion will remember the Z position you just set.

Zeroing Tips

• Zeroing Speed
  • Use larger increments to move the router roughly into place, then user smaller increments to fine-tune your zero positions
  • Moving too fast while zeroing Z can cause damage to your stock, particularly if your stock is soft in nature (e.g. softwood like pine)
• Zeroing Z
  • Zero your Z to the highest point on your stock, particularly if you're cutting an uneven stock (e.g., warped wood)
  • If you get a warning when you attempt to run your cut that your project's Z plunge is deeper than the machine can go, try pulling your bit shank out a bit (but keep it inserted at least 1")
  • We use the paper wiggle test to set zero. Use the piece of paper kept under the CNC machine. Place it over your stock, then lower the router until you feel a bit of resistance/scratch when wiggling the paper beneath the bit. The paper should still move without too much effort.
• Zeroing X and Y
  • It is helpful to use the same zero orientation you used while designing your project in Carbide Create when you set your X and Y zero position in Carbide Motion. In other words, if zero is set as bottom left in Carbide Create, set the XY zero to the bottom left of your stock in Carbide Motion, etc.
• Rapid Repositioning:
  • Once you zero X and Y, Carbide Motion stores their position data. If you need to come back to your XY zero quickly, you can click "Rapid Position" and then click the option to return to your most recent XY zero
  • The same is true for your Z zero, except that Carbide Motion will give you a 6 mm buffer to protect your stock from accidental damage. You will need to re-zero Z to account for that 6 mm
  • This data is stored in Carbide Motion, not the CNC machine. If you need to come back to a cut, especially since AHA's machines are used by multiple makers, your rapid position X, Y, and Z may be lost

Step 5: Load Your Project File

1. Click "Run" in the top right of the Carbide Motion window
2. Click "Load New File" and select your project file (file extension: .c2d)
3. Double check all the preview options (Top, Profile, and ISO views) to be certain you loaded the right file
   • The ISO preview is especially important, as it will show you the toolpaths that the CNC machine will take to cut your project. It is a great view for catching errors before you begin cutting.
4. Once you have checked your previews, click "Done" and you should now see your file's name, X/Y/Z path extent data, and approximate run time in the Carbide Motion window

Step 6: Start the CNC Machine

1. Click "Start Job"
   • A window will popup telling you to insert your tool. You did that in #Step 2: Insert the Appropriate Bit, so just click Resume
2. In the Run Job window, click "Start"
3. A window will pop up telling you to set the spindle speed but do not click Resume until the spindle speed is set, the vacuum is attached and turned on, and the router is turned on
   1. Set the spindle speed using the red dial on top of the router
   2. Connect the vacuum hose to the brush assembly and turn on the vacuum using the red switch on the front of the vacuum lid
   3. Turn on the router using the black switch on the right side of the router]
4. When everything is running, click "Resume" on the spindle speed pop up and watch the machine cut your piece!

Step 7: Clean Up & Reset the CNC Machine

Once you are done, please return everything back the way you found it so that the next person to use the machine can do so without having to clean up after your project or go searching for parts or tools.

1. Before you start cleaning up, be sure to turn off the the router (use the black switch on the router body), and the Shapeoko as a whole (use the red switch on the cord)
2. Remove the vacuum brush and clean out any debris left from your cut
3. Remove the bit you used, place it back in its protective case, and put it away with the other bits
4. Vacuum up debris from the Shapeoko, your project, and surrounding desk area
   • If you haven't already done so, please check the vacuum and empty it if it is full
   • ⚠️ An over-full vacuum is a fire hazard ⚠️ - if you forgot to check before you start, please make sure to check when you are done
5. Sweep up any debris from the floor of the CNC room
6. Do not shut down the computer - you can instead place it in Sleep mode
7. If you're the last person in the CNC & Loud Noise rooms, turn off the lights as you leave

Shapeoko 3 Pen Plotter (Small CNC Machine)

Operating steps for using the small CNC machine as a pen plotter to draw portraits or other pictures are forthcoming.

Shapeoko 3 XXL

Operating steps for the larger Shapeoko are forthcoming.

Vocab

• Bit: A bit, in CNC machining, is a cutting tool inserted into the CNC machine that is used to cut away material from your stock. There are many different kinds of bits. Some of these include: router bits, which are most often used for woodworking, v-bits (a.k.a, chamfer bits) are a type milling bit used to make sloped cuts (e.g., letter engraving, bevel/chamfer edging, etc.), end mills which are designed to cut using the circumference of their cutting edge and are used for contouring, profiling, pocketing, and many other types of cuts, etc. The words "bit" and "mill" may sometimes be used interchangeably, though there are differences. AHA currently only has milling bits, so if you are using AHA's bits, you will be inserting either an End Mill or a V-Cut Mill (usually referred to in the space using the brand name VCarve). Bits consist of a shank, flutes, teeth, and tips.
  • Shank: The shank is the non-cutting end of the End Mill that is inserted up into the router.
  • Flutes: The channels that are formed between the teeth, or the cutting edges, at the cutting end of the End Mill. The flutes channel the chips of material being removed from the stock away from the stock. There are two types of flutes; straight flutes and spiral flutes. Spiral flutes are further divided into two types: upcut flutes (which pulls chips of material up and away from the stock) and downcut flutes (which pushes chips down toward the stock).
  • Teeth: The cutting edges of the End Mill.
  • Tip: The tip of the bit. There are many different tip shapes, and these produce a different shape of cut as they tip engages with the stock.
• Collet:
• Stock: In CNC machining, stock is a solid piece of material that will have some of that material removed by the router. Depending on the machine type and tools, your stock may be metal, wood, plastic, or (for pen plotters) paper.
• Spoilboard: A spoilboard is a disposable work area. This part of the machine often gets gouged or otherwise damaged - but don't worry, that's what it's there for! It takes the gouges so the CNC machine doesn't have to.
  • There are different types of spoilboard set ups. The small CNC machine uses a threaded insert grid spoilboard. It is made by drilling a grid into the spoilboard material and adding threaded inserts into the holes. Bolts are then inserted through a clamp and tightened into the threaded insert to apply downward pressure on the stock, securing it in place.
• Step Clamps: Step Clamps consist of three parts. The Clamp part is long, with one tapered, blunt end, and one angled, serrated end, with an oblong hole in the center. The Block part is a right triangle with a serrated hypotenuse . The Bolt is just that - a bolt - that is inserted into the hole in the clamp and threaded down into the threaded inserts in the spoilboard. The Clamp's tapered end sits on top of your stock, and its serrated end is supported by the serrated edge of the Block. The Bolt holds the Clamp in place, and causes the Clamp to exert downward pressure on the stock to keep it still. A video demonstration of how to use a Step Clamp in a Threaded Spoilboard is available from the Inventables channel on YouTube
• Threaded Inserts: Threaded inserts are inserted into an object to make a threaded hole.