Author Topic: My new tool  (Read 3172 times)

0 Members and 1 Guest are viewing this topic.

Offline TomahawkLabs

  • Thread Starter
  • Posts: 172
My new tool
« on: Wed, 15 January 2025, 17:23:55 »
Howdy everyone. I wanted to share my newest toy, I mean tool, The Shapeoko 5 Pro 2'x4'. The machine lives in a box for purposes of cleanliness in my garage and for sound level reduction.

Let's start with the box. The box is made from laminated 2x4s, laminated 2x6s, 0.75" plywood, 0.125" 1lb/sqft mass loaded vinyl (MLV), 3.5" polystyrene, 0.25" acrylic sheets, sound dampening foam, and 0.5" x 0.25" foam gasket tape. The box construction idea was 100% stolen from this video. The core of the design is using 2x4s to create a frame. That frame is covered with the MLV. Then the plywood as attached to the frame. The MLV acts as both mass and decoupling for the layers of wood. The cavities of the frame are filled as tight as possible with polystyrene, before being covered by more plywood.

The lower chamber is integrated with posts (two 2x4s screwed together) to create the lower half. The lower chamber has an additional passageway that is lined with sound dampening foam to allow the passage of cables/electricity into the enclosure. You will also find 2 additional spaces. The intention was to force cool air in, and force hot air out. The original use for the lower chamber was to house the electronics and a vacuum. Unfortunately, the CNC has the wiring come out of the right side of the machine and it is not long enough to live in the lower chamber.

The door is made with the same techniques as the framing/shell with a polysyrene core. Currently, the lower purpose exists to hold my laptop while the machine is running. Next to the opening is my toolbox. the height of this box was specifically designed to fit that toolbox. 10/10 worth the time investment.

The upper half. Same construction as the lower half with the expection of the doors. The doors are instead made with a core of 4 0.25" an airgap of unknown depth, and the doors are air sealed using 2 layers of the gasket tape with an air gap between the gaskets. The doors are notched where they meet, where we find 3 layers of gasket tape.

The machine. The machine is a Shapeoko 5 Pro 2x4. The cutting tool was planned to be the 110v VFD spindle, but once I read the fine print I realized it was not possible. Electrical code where I live requires the use of GFCI outlets in garages (and around water) and something about how VFD spindles work will trip breakers. So I went with their er-11 compact router. It being ER-11 did 2 things, it was cheaper since they were discontinuing the model due to lack of interest and it allows for greater expansion as ER-11 is the standard with CNC, finding unique bits should be easier. Some highlights of this CNC are that it uses ball screws instead of belts. This helps with rigidity and requires less maintenance and tuning than belts. It also uses linear rails to assist even further with rigidity and to keep tolerance nice and tight. The machine has a rough cutting area of just over 24" x 48".

The goal for this machine is to make keyboards from scratch. I have long desired to build my own keyboard. That is, designing the PCB, milling the plate and case, and the required finishing work. There is lots of learning to do, but right now, I am happy. If anyone else has any experience with the design/manufacturing of keyboards at home, I would love to know.
« Last Edit: Wed, 15 January 2025, 18:46:06 by TomahawkLabs »
Always looking for Alps SKCM/SKCL switches. Feel free to DM.
AMD 5600x | RTX3080 | 2x 1TB NVME + 4x 4TB HDD | B550M Pro-P | 32GB RAM | RM850x | Node 804 | Schiit Modius/Magnius + Audeze LCD-2 | 2x Dell S3422DWG
GMMK 1 Full Size Barebones | Zealio 67g ; Apple M3501 handwired | Alps SKCM Damped Cream
SA: Camping

Offline TomahawkLabs

  • Thread Starter
  • Posts: 172
Re: My new tool
« Reply #1 on: Wed, 15 January 2025, 17:54:12 »
Reserved
« Last Edit: Wed, 15 January 2025, 18:46:24 by TomahawkLabs »
Always looking for Alps SKCM/SKCL switches. Feel free to DM.
AMD 5600x | RTX3080 | 2x 1TB NVME + 4x 4TB HDD | B550M Pro-P | 32GB RAM | RM850x | Node 804 | Schiit Modius/Magnius + Audeze LCD-2 | 2x Dell S3422DWG
GMMK 1 Full Size Barebones | Zealio 67g ; Apple M3501 handwired | Alps SKCM Damped Cream
SA: Camping

Offline fpazos

  • Posts: 170
Re: My new tool
« Reply #2 on: Thu, 16 January 2025, 01:02:40 »
This is really cool, nicest diy enclosure I've ever seen.

Enviado desde mi 23122PCD1G mediante Tapatalk

 

Offline wjrii

  • Posts: 128
  • Location: Texas
Re: My new tool
« Reply #3 on: Fri, 31 January 2025, 20:39:44 »
Very cool.  I make my own keyboards from RP2040's, a cheap diode laser, and a cheaper 3D Printer.  I've sent out one completely unpopulated through-hole PCB to be made, which worked as intended, and my xometry order of aluminum switch-plates also went reasonably well.  I doubt I could teach you anything, but I'm enthusiastic to see what you come up with.

Offline kurplop

  • THE HERO WE DON'T DESERVE
  • Posts: 996
Re: My new tool
« Reply #4 on: Fri, 31 January 2025, 21:08:42 »
I’m excited for you. It looks like a nice mill. Are you planning on using aluminum for the keyboards?

Offline TomahawkLabs

  • Thread Starter
  • Posts: 172
Re: My new tool
« Reply #5 on: Sat, 01 February 2025, 07:43:22 »
I’m excited for you. It looks like a nice mill. Are you planning on using aluminum for the keyboards?

While it can do aluminum, I am a more interested in wood cases. I do plan to experiment with aluminum, brass, other unique plate materials. I am not 100% sure that the surface finish would be up to snuff with the tool I have, but would be fun to test!
Always looking for Alps SKCM/SKCL switches. Feel free to DM.
AMD 5600x | RTX3080 | 2x 1TB NVME + 4x 4TB HDD | B550M Pro-P | 32GB RAM | RM850x | Node 804 | Schiit Modius/Magnius + Audeze LCD-2 | 2x Dell S3422DWG
GMMK 1 Full Size Barebones | Zealio 67g ; Apple M3501 handwired | Alps SKCM Damped Cream
SA: Camping

Offline kurplop

  • THE HERO WE DON'T DESERVE
  • Posts: 996
Re: My new tool
« Reply #6 on: Sat, 01 February 2025, 09:01:28 »
I’m excited for you. It looks like a nice mill. Are you planning on using aluminum for the keyboards?

While it can do aluminum, I am a more interested in wood cases. I do plan to experiment with aluminum, brass, other unique plate materials. I am not 100% sure that the surface finish would be up to snuff with the tool I have, but would be fun to test!

Power isn’t the issue. Rigidity of the frame is. Slow shallow cuts become necessary but the finished product should turn out fine. Whenever I mill aluminum, I usually sand out the milling marks then sandblast to get a uniform matte finish.

Offline TomahawkLabs

  • Thread Starter
  • Posts: 172
Re: My new tool
« Reply #7 on: Sat, 01 February 2025, 09:19:54 »
Do you do any sort of active cooling for the aluminum to avoid it getting "gummy", or does the shallow cuts relieve the need for active cooling? I've really only experimented with the scrap plywood.

I specifically chose the Shapeoko 5 Pro because it had both linear rails and ball screws. I am hoping those upgrades will make cutting metal that much quicker. Additionally, I am not a full time shop where time=money. I just like seeing scraps fly. I have looked at the Harbor Freight sand blasting enclosure in the past, maybe it does have a place in my garage.

Where do you find metal stock. I can't seem to find online sellers that aren't industrial. I was specifically looking for 1.2mm plate and interested in where to find thicker/wider brass stock for weights.
Always looking for Alps SKCM/SKCL switches. Feel free to DM.
AMD 5600x | RTX3080 | 2x 1TB NVME + 4x 4TB HDD | B550M Pro-P | 32GB RAM | RM850x | Node 804 | Schiit Modius/Magnius + Audeze LCD-2 | 2x Dell S3422DWG
GMMK 1 Full Size Barebones | Zealio 67g ; Apple M3501 handwired | Alps SKCM Damped Cream
SA: Camping

Offline kurplop

  • THE HERO WE DON'T DESERVE
  • Posts: 996
Re: My new tool
« Reply #8 on: Sat, 01 February 2025, 13:43:40 »
I run compressed air directed at the cut which has a cooling effect, especially if their air has water in it (not added but from ambient air condensing in the tank). Shallow, fast feed keeps the metal from building up excessive heat.
I have a local metal supplier that sells cutoffs for a discounted price. They usually have 6061 in sizes I can work with. I bought brass rod online one time as well as some plastics but I don’t remember the company name.

Offline TomahawkLabs

  • Thread Starter
  • Posts: 172
Re: My new tool
« Reply #9 on: Sat, 01 February 2025, 14:05:30 »
Ok, when I built the enclosure I did run some air lines for that exact reason. Just need the regulator, etc. I’ll check locally for stock.
Always looking for Alps SKCM/SKCL switches. Feel free to DM.
AMD 5600x | RTX3080 | 2x 1TB NVME + 4x 4TB HDD | B550M Pro-P | 32GB RAM | RM850x | Node 804 | Schiit Modius/Magnius + Audeze LCD-2 | 2x Dell S3422DWG
GMMK 1 Full Size Barebones | Zealio 67g ; Apple M3501 handwired | Alps SKCM Damped Cream
SA: Camping

Offline Findecanor

  • Posts: 5070
  • Location: Koriko
Re: My new tool
« Reply #10 on: Sun, 02 February 2025, 05:22:08 »
I wasn't sure what it was I was seeing before I clicked an image and got it in the correct orientation. :P
🍉