Highlighted Projects
Ongoing
Self-Build CNC Machine Project
Overview
As a personal side project, I embarked on designing and prototyping a fully custom 3-axis CNC router machine, with the capability to fold up for vertical storage and the potential to upgrade to a total of 8 axes. This machine features an advanced setup with four Nema 23 (2.2Nm) closed-loop stepper motors driving ball screws (dual Y-axis) and a powerful 2.2kW water-cooled spindle with a temperature reader. The working surface spans 1500x1500x110mm (X – Y – Z). The chassis is constructed from aluminum profiles and connection plates, incorporating 3D-printed drag chains and a robust control box equipped with dual 20A inputs (VFD on a separate circuit) and essential safety mechanisms, including breakers, fuses, and a dual latching circuit.
Design Approach
The project commenced with the development of the Y- (comprising Y and A axes) and X-axes. I handcrafted the connection plates from solid aluminum plates. Following this, I designed and fabricated the Z-axis and the spindle mount, which features adjustable Tamming screws for precise alignment of the spindle to the X and Y axes. For efficient cooling, a PC water cooling system is mounted on the back of the X-axis. This system includes a pump, reservoir, three speed-controllable fans, and a radiator, manually monitored by a temperature reader, with optional future integration of automated speed control for fans and pump.
The electrical schematic for the control box was meticulously drawn on paper before assembly. The control box itself is ventilated by six fans and constructed from an electrical enclosure with dedicated in- and output ports at the underside for each cable leading to motors, sensors, the pump, spindle, fans, and more. The front of the control box features on/off switches at various circuit stages, as well as a hard E-stop. Additionally, there are two software E-stops connected via cable: one on the machine itself (at the water cooling control box) and a portable one. The control box also includes a brake resistor for the spindle and the spindle’s VFD. All cables from the controller and power supplies are patched in DIN rail connectors for straightforward maintenance and disconnection. Each power supply, controller, and stepper motor driver is protected by separate fuses.
A secondary control box manages the cooling system, featuring on/off buttons for the fans and pump, as well as a speed potentiometer for the fans and the aforementioned fixed soft E-stop.
Proximity sensors are installed at each end of the Y & A, X, and Z axes as limit switches and for homing. The control box can accommodate additional separate homing sensors. The Y and A limit sensors are used for squaring the Y and X axes. A Z-axis touch plate is included for zeroing the Z-axis on the material.
Additional Features
The CNC machine’s base includes provisions for a dust collection system, utilizing a 3D-printed centrifugal dust separator that directs debris into two separate bins before reaching the blower. Beneath the blower, there’s a dedicated compartment for a desktop computer running MACH4 software. The spindle is equipped with a 3D-printed dust shoe featuring a detachable brush, ensuring visibility during setup and effective dust collection.
All electrical connections at the machine are designed with detachable connectors at the motors and sensors, housed in an electrical box at each end of every axis. The cabling is drag chain-suited, shielded, and neatly run through cable gutters and drag chains to each location on the machine, ensuring a clean and organized build.
This project showcases a comprehensive approach to designing and building a highly functional DIY CNC machine, reflecting a commitment to precision, safety, and modularity.
Date
Deer Tone 2x15" Bass Guitar Speaker Cabinet
Overview
Experience the harmonious blend of craftsmanship and acoustical engineering with this self-build speaker cabinet, tailored specifically for bass guitar amplification.
Design and Build:
This speaker cabinet is meticulously constructed from premium Padouk hardwood. Known for its distinct metallic resonance, Padouk is chosen to enhance the clarity of high and mid frequencies, resulting in a uniquely balanced and dynamic sound. The cabinet houses two 15-inch Eminence Legend BP 1525 A speakers, each residing in its own separate chamber to ensure optimal sound isolation and performance.
Acoustic Engineering:
Each chamber is equipped with thermoformed aero ports, precisely tuned to 80Hz to deliver powerful and controlled low-end frequencies. The inclusion of polyfill within the chambers further refines the sound by reducing internal reflections and standing waves, ensuring a pure and accurate audio output.
Practical Features:
- Mobility: The cabinet is designed with solid wooden feet, kick-back handles, and wheels, making it easy to maneuver on stage or in the studio.
- Handling: Multiple carrying handles are strategically placed on the sides, top, and bottom of the cabinet, providing versatile options for lifting and transporting.
- Protection: To safeguard the cabinet from wear and tear, the corners are reinforced, and additional protection is provided for the placement of your foot when tilting the cabinet onto its wheels.
- Aesthetics: The final touch is a laser-engraved logo, adding a mark of distinction and craftsmanship to this functional piece of art.
This self-build speaker cabinet is more than just an audio device; it is a testament to the integration of superior materials, acoustic precision, and practical design, culminating in an unparalleled amplification experience for bass guitarists.
