3d print/CNC Panel

This is a prototype panel designed and fabricated by Jared and Brian at the University of Nebraska - Lincoln. We started with a base image of water ripples and used it as a bump map to create a three dimensional form in Rhino. From there, we initiated the first phase of a two machine process. The first iteration was done with the 3D printer (2nd Image). By looking at this, we came to a few conclusions on how to switch between phases. The whole process was to design something as ornamental patterns and eventually get them constructed in panel form. With some changes to our file, we then proceeded to change the scale when taking it into RhinoCAM. We had to do this in order to size our configuration to the correct stock and orient it in way to be manufactured on the CNC (3rd Image). To do this process, we had to use 3 different tool paths. The first, which fullfilled our 2D requirement, was done with profiling and a 1/8" flatmill bit. It took over an hour to do since our finish depth was done in two passes. The second path which started our 3D impression was a path called Horizontal Roughing. We struggled to get settings to minimize the time it would take. We decided to use a 1/2" flatmill bit and to bump up feed rates. This allowed us to complete the roughing in under an hour. The next step which fulfills our 2.5D requirement was a horizontal finishing path. Since we had quite a bit of material to mill yet, we chose a 1/4" ballmill bit to do this step. It gave a descent finish but since the pattern only goes one direction, the grooves between passes were still significant and not giving us the smooth finish we had hoped for. Since we had finished this step in under an hour, we decided to go ahead and do another horizontal finishing path. We ran the same tool path, but regenerated it with a 1/8" ball mill bit. This significantly reduced the grooves and gave us a much smoother finish which was desired.