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smart machinery - intelligent price |
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Intelicam |
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Frequently Asked Questions |
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Yes. The controller automatically translates the G-code into individual commands sent to each motor so that the final movement of the business end of the cutting tip looks fluid. Some models are available with an optional 4th rotational axis but still moves in 3-axis simultaneously. |
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Do Intelicam machines move in three-axis simultaneously? |
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Yes, the three axis routers can cut in 3D. The preferred file format of the 3D object is STL, which is the most generic 3D file format available. This file is brought into the Cut3D CAM software. In a step by step process you describe how you want the object to be cut. There is the ability to cut only one side or multiple sides by rotating the material. You can also resize the object, reduce or exaggerate the 3D contours (Z-axis), choose from a variety of router bits. Cut3D automatically generates the g-code. The process produces remarkable results with very little effort. |
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Can the Intelicam machines cut in 3D? |
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The intelicam is a high quality industrial CNC machine, built to precision standards and definitely without cutting corners. We can bring them to the market at much more affordable prices than the we could in the past due to our proprietary manufacturing and component sourcing. Our experience and our network gives us an advantage to choose the best parts at the best price. That’s what we do and this allows us to offer low prices while remaining a strong viable business—which means we’ll be around for decades to come. |
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Why are machines so low priced? Are they missing anything? |
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Delivery times vary depending on availability of stock, from one week up to 8 to 12 weeks for a custom order machine. Please ask the sales person for available stock. |
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How long does it take to receive the machinery once ordered. |
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Yes, but don’t be confused as there are two main types of CNC machines and the common definition of Machining Centers usually refer to machines in metal fabrication shops that cut and shape steel blocks (Type 1). These machines are usually enclosed by large housings to contain the cutting lubricant. Intelicam machines (Type 2) are mostly open gantry based machines (except the intelicam mini-mill which is enclosed for sound and safety reasons). Intelicam type CNCs cut and shape a wide range of flat material including wood, plastics, aluminum. Both Type 1 & 2 CNC machines use G-code based CNC control. G-codes are “move-to” instructions that define a specific location in the X,Y,Z space, as well as feed rate (speed) and other instructions like turning on the spindle and other instructions the machine needs to operate. It is unlikely that a metal machine shop would have an intelicam “type 2” CNC, just as it is unlikely that a sign maker or millwright shop would have a “type 1” machine, though both groups may well call the machinery a CNC Machining Center. |
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Are the Intelicam machines “CNC Machining Centers”? |
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How does it work? The machine controller reads the picture the same way a printer reads a picture, but instead of firing ink the laser fires a burst of energy which burns the wood or explodes the granite. The result is stunning and permanent. The process to go from scan to laser setup usually takes just a few minutes. It’s that easy! |
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How does the laser create pictures? |
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What is a vector, and how does a CNC use a vector? |
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A vector is a line drawing done on a computer that defines the outline of a shape. In real terms it's a mathematical representation of that line. If you looked at the shape drawn on a sheet of graph paper where the X direction is along the bottom and the Y direction is going up the side, each point along the line could also be represented as an X,Y coordinate. A CNC router follows the x,y coordinates of each point along that line when it cuts out the shape. If the shape has depth, then there is another coordinate added in the Z direction (thickness). That's why a cnc router is often called a three-axis cnc, because it can move to (and thus cut) the three coordinates X,Y,Z at any point on the shape. That's all it does. |
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No. The machines only follow precise instructions from the CAM file (usually called the toolpath and written in the machine language of G-code). They are good at following instructions, and they don’t need a lunch break or ask for a raise, but there is no inherent intelligence in the control system. |
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Does the CNC anticipate what I want cut and correct for mistakes? |
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Not quite. There are three separate steps for making an object on the CNC. They are (1) CAD; (2) CAM; and (3) Machine setup. The Intelicam machines come standard with all you need to complete these three stages. The one exception is if you are wanting to create a 3D file from scratch you will need to acquire separate 3D design software. Here are the three stages: 1. First stage is to ensure the design file, called the CAD file, is in vector format (like dxf, eps, plt or ai), and not raster format (like jpeg, bmp, tiff). Vector is based on lines and outlines. Raster, of which a photograph is one type, is based on a grid of pixels, or points. V-Carve Pro, which comes with the Intelicam routers, has an easy to use utility to convert raster into vector files. But count on some extra time to clean up the finished conversion before cutting. V-Carve Pro also has some excellent design tools built into the software. I created the Intelicam logo quite easily using only a few design tools in V-Carve Pro. A lot of clipart is vector based (you can tell by its saved format). If you’re not changing your clipart then the first stage is already completed. As a bonus if you want to make changes, vector files are easily adjusted right in V-Carve Pro. 2. Second stage is the CAM. This stands for computer aided machining. The goal of this stage is to create the set of instructions, called a toolpath, that the intelicam machine will understand to cut the object out of real material. It’s easier than it sounds. Toolpathing is included in V-Carve Pro. It’s a simple step-by-step procedure, leaving very little room for messing up. You do not have to “program” the computer. It’s more like a video game where you just pick the various inputs and let the game create its own results. Inputs include material dimensions, tool diameter and shape (all preloaded in V-Carve Pro), depth of cut, starting points, and cutting strategy, for example, if you want the cut out part released from the material or held in place with tabs so it won’t be damaged if it moves. You may decide to use a bigger roughing tool and then switch to a more slender finishing tool. With the click of a button V-Carve Pro automatically generates the toolpath. The path is graphically displayed and can be examined in three dimensions. You can preview the finished toolpath. The simulation is remarkably true to the finished result, even accounting for stepover patterns, material color and grain. If it doesn’t look right on the computer then it won’t look right when it’s finished. The simulation also gives you statistics, like machine run-time, maximum cutting depths. For many clipart designs, of say a drawing of a swordfish, the CAM stage can be completed in less than one minute. The final stage is to save the CAM file as an intelicam “.nc” file - a one button procedure. The saved file is detected automatically by the intelicam machine controller ready for cutting. Even complex 3D toolpaths that generate hundreds of thousands of lines of g-code, the CAM stage seldom takes more than 5 minutes. 3. The third stage occurs at the machine. Secure your material to the machine surface using standard clamps or optional vacuum hold-down. At this point is important that the machine setup matches the CAM setup. You must use the input parameters created during the CAM stage. Generally there are only three things to remember: (1) ensure the material dimensions match the CAM settings; (2) insert the correct tool bit (diameter and shape) into the router; and (3) set a home position (0,0,0) to match the CAM file. Usually the home position is the upper left corner of the material but it could also be the center or any other corner. Setting home involves zeroing the machine’s XY coordinates at the home you chose in the file, then zeroing the Z-axis at the proper height (most often it’s aligning the tip of the cutter with the top of the material you wish to cut). Intelicam routers make zeroing the Z-axis easy by using the material height sensor that comes standard with the machinery. Now all you do is select the name of your CAM file and click START. The spindle powers up before cutting begins and powers down after cutting ends. |
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What’s the process? Can I choose any type of clipart and just send it to the router for cutting? |
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I’ll first define CNC then Axis. CNC (computer numeric control) is a generic term used by several different classes of automated machinery that turn CAD files (computer based designs, like clip-art or user generated) into tangible objects. Using instructions generated by a toolpath file (called a CAM file) the CNC machine automatically coordinates all it’s moving parts using motors that respond to precise instructions to position the tip of a cutter in three dimensional space (X,Y,Z coordinates) to cut and shape material. An axis is a movement of freedom that follows the straight lines of a 3D grid, or straight movement combined with a rotational movement. Most of the intelicam routers are controlled in three axis along a straight plane. Intelicam machinery cuts flat material on an X,Y,Z plane. Facing the front of the machine the X-axis is the width across the gantry, the Y-axis is the length from front to back, and the Z-axis is the up down movement of the cutter head moving into the thickness of the material. A lather option can also be mounted to a three axis flatbed router, but the rotational axis is precisely indexed as a substituted for the Y-axis. Other types of common three-axis CNCs include waterjets, laser cutters, plasma cutters and plotters. |
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What does a three-axis CNC mean? |
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Intelicam Specific Questions |
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General CNC related questions |
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We are a boat designer and our company’s boat plans are all hand drawings which we sell to do-it-yourself boat builders. We are often asked to convert to digital format but are worried about the files being to transportable, stolen and we won’t get paid for our work? Any comment? |
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This is a deeply debated subject among people who make it their business to sell designs. Having spent most of my professional life developing, building and selling (not to mention using) cnc routers I can add some weight to the argument. I fully understand the fear of copyright piracy. The music industry is undergoing a fundamental transformation because of it. The files do become transportable, but my experience is that even if, as a worst case scenario, you find your files widely available very few will use the files to build anything without your permission with the addition of one simple step: “Offer a value “associated” with the files to make it not worthwhile to proceed with construction unless they have you on their side.” Make your benefit go beyond the actual files. For instance offer registered users up to date “how-to-make-it” plans that complement the files. Or you can capture additional value such as fee for service advice, design changes, special fittings, etc. Sure you have to evolve your business practices a little, but that’s the nature of things. Remember, the files are just shapes. Shapes do not make a boat. And if you’re still concerned, here’s the biggest misconception about CNC: the cnc does not build the boat. Of course everyone knows that, but I don’t think they understand it, or the discussions among forum members would have focused on this. The CNC machine is a dumb, stupid machine that happens to follow instructions perfectly (and doesn’t ask for a raise). It’s still only a tool, albeit a pretty cool tool. In the vast amount of work required to build a boat, even a small canoe, the CNC just makes starting out a lot easier. But in the end nobody looses their hand/eye skills; it’s still a lot of work and the boat builder still makes the transformation from nice guy with a dream into grumpy eccentric. With a CNC they just do it quicker. We live in a digital age. It’s easy to convert plans into digital files but if you’re in charge of this process you can benefit if would-be builders know where to turn to when they actually attempt to build it. A CNC router moves the project forward a little faster. And my guess, and this is only a guess, if good CAD files and instructions were made available, it would increase the number of backyard boat builders toiling away at a long dormant dream. And in my opinion that can only ever be a good thing.
Click here for a link to companies with boat plans available as digital vector files |
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Yes. The auto calibrating tool makes it easy for you to manually change tools and establish the new height without any special jigs or rigging. Here is the process: 1. Starting with your file (2D or 3D file) create the toolpath for one job file using 5 different tools, T1 thru T5. Don’t be concerned about anything at this point except ensuring that the simulation in the toolpath software matches the desired output. 2. The only special consideration is that if you are cutting away the material surface so that you have no original surface reference point after any of the tools finish cutting, then you must setup the material parameters so Z- zero is at the bottom of the material instead of the usual top. If you forget to do this until afterward, or change your mind, you can change it later and click “recalculate all toolpaths” to make the change in the actual toolpath files. 3. Instead of saving one toolpath file to the machine, you simply select and save each toolpath step associated with each tool. Use a naming convention that is easy to remember, for instance, call the file the job number then T1, T2, ,T5 4. Put tool 1 in the spindle, then put the tool calibrator on the machine bed (or affix it semi-permanently on the bed). Position and X,Y workplace origin (0,0) to match the origin in the toolpath file (upper right, middle, lower left). Place the calibrator under the tool in the spindle, then click calibrate the Z height using the auto calibrator. It automatically turns Z to zero at the proper height to match the tool. 5. On the controller, open and run job file called FileT1, or whatever you called it. 6. It’ll stop and return to start point when finished 7. Physically change the spindle tool to T2. 8. Without resetting the origin position of XY, move machine to your auto tool calibration point and recalibrate the Z with the new tool in it, (this is a one button action). The new Z is now automatically reset to match T2. 9. (You could write a macro to move the desired XY position if you have the tool calibrator always at a known location, but that sometimes is just a waste of time) 10. Load and run FileT2. 11. Repeat steps 6, 7 & 8 until job is done.
The calibration tool comes with every Intelicam router. It works well for calibrating multiple tools in a non-intensive production environment. |
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Can I use multiple tools for the same file even though I don’t have a tool changer? |
