CarBEN Model -- 1/24th scale model and 3D computer model for EV

[NeilBlanchard]

Okay -- the first 2 boxes contained the MDF parts, and the rest of the hardware, etc. arrived yesterday. I have started to assemble the gantry.

The software will require a fair bit of learning, and I will be juggling 3 programs to get what I need.

Let the fun begin!

[kach22i]

It's nice to be able to get these sort of tools, I admire what you are doing.

Just an FYI, in a few communities there are workshop type clubs with lots of equipment.

Ann Arbor, MI:
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[Rokeby]

Originally Posted by NeilBlanchard

It may have been someone here who first suggested t?

Neil,

That was probably me, either way-earlier in this thread or in the 1/24 scale
model thread.

I'm glad to hear that the Phlatprinter will be useful. I didn't realize that it is
3D. All the better for you.

One possible caution. Cutting the foam is going to make a lot of
electrostatically charged dust. Should it get sucked into your router's motor
cooling air ports it could goober things up in short time. I'd watch the unit in
operation and make (eco)mods as necessary.

Can't wait to see pics/video of your unit in operation.

[NeilBlanchard]

Pictures of the Phlatprinter III build will be posted soon...

[NeilBlanchard]

I've gotten past the halfway point! The circuit boards are now on, and the sides and the base are next.

There is a vacuum hose connected to the cutter head and it is routed through a little plenum to pull in dust from just above the spinning bit.

[NeilBlanchard]

I picked it up where I left off last weekend, and it is now phinished and working!










Here's a video of it running a test file (without the cutting bit powered up):


The front edge of Irene is raining down on us, and tomorrow I start to delve into getting the g-code files I need to start cutting the 2" thick sections of CarBEN EV!

[Dunkler]

Neil, I am always impressed with the projects you post. I am really excited to see how the CarBEN EV turns out!

[NeilBlanchard]

Here's a screen capture of my initial try at laying out the 2'x8' sheet of foam in DataCAD:



In the upper right is an approximate layout of the first 2" thick foam sheet, to be cut on on my PhlatPrinter III. I need to redo it with an alignment "rod" in the SketchUp model, that will appear as 1/2" circles, like those shown on the red F2 section. I'll use dowels to align the sections as I glue them together.

I need to confirm the limits of the cutting area -- I think the righthand edge needs a 4" band (on the 2' side) so that the X-axis friction rollers can keep hold of the sheet? And that means the F2-5 red piece will need to be moved up to the second 2'x8' foam sheet.

I also need to separate the doors, hood, wheel skirts, etc. so they can be made as pieces, and I'll have to design hinges for all of them.

[CFECO]

That, is some very nice work Neil!

[kach22i]

Neil, I just kept clicking "NEXT" in that image link. Pure entertainment, I admire the work you are doing.

I'm trying to picture how a 2 foot by 8 foot by 2 inch piece of foam is going to be fed into that cutter/printer. Another video in the future might help.