RAZOR KNIFE

CUTTING MAT

WIRE CUTTERS

MARKING TOOLS

PLIERS

CIRCLE STENCIL

SMALL WOOD SAW

COMPASS

12 METAL RULER*

> 16 RULER

HOT GLUE GUN

RIGHT TRIANGLE

SCREWDRIVER

Find a sturdy table that is in a

well-lit area. Ideally youll be
working with 40 x 30 sheets, so
a suitably sized surface will help.

A large piece of cardboard will

do, but I would highly recommend a cutting mat. Mine is
18x24 and made by Artool.

I use an ultra fine point black

Sharpie, but if youd prefer, a
pencil and eraser will work as
well.

The two hole diameters which

youll need to mark are 5/8 and
1-1/8. A compass will work just
as well.

A substitute for the circle stencil.

Highly recommended. A 24
C-Thru ruler will make your life
much easier. Make sure that it
has 1/16 markings throughout.

These instructions are designed

to take advantage of the
factory-square edges of the
foamcore. This tool is optional.
ILAN E. MOYER

SHEET 1/15

WORK SURFACE

I highly recommend getting an

Olfa knife. It is difficult to cut 1/2
foamcore with just an Exacto.

These will be important for

cutting thin steel cable and
stripping the stepper motor
wires.

A needle-nose or any other

variety will work well.

If you want to save money and

use wooden dowels, youll need
this to cut them to length. A real
saw works even better.

I cut everything freehand, but if

youre bad at cutting straight
lines or want to better protect
your fingers, grab one of these.

Mine is made by Surebonder and

has both a high and low
temperature setting. I run it at
high.

Youll need a medium sized flat

head screwdriver.

066 FOAMCORE CNC: VISUAL TOOL GLOSSARY

3/17/2011

ALUMINUM SHAFTS

WIRE ROPE

QTY: 3
McMaster-Carr

QTY: 25 FT
McMaster-Carr

These shafts are made to be very straight with

highly accurate diameters. They are responsible
for both moving and guiding the toolhead and
the Z axis table. 1/2 diameter x 15 long.
$9.00 EA, $27.00 TOTAL
P/N 1031K14

$0.41/FT , $10.25 TOTAL

P/N 8930T22

DOUBLE-STICK TAPE

QTY: 2 PACKS
McMaster-Carr

QTY: 1 ROLL
McMaster-Carr

$3.15 /PK, $6.30 TOTAL

P/N 6389K623

An adhesive-paper-adhesive sandwich.
Double-stick tape is used to laminate the delrin
strips to the foamcore, as well as generally to
stick things together.
$7.93 /ROLL, $7.93 TOTAL
P/N 76405A13

CONSTANT-FORCE SPRING

ELECTRICAL TAPE*

QTY: 1
McMaster-Carr

Local Hardware Store

This tape-measure-like spring unravels with

consistent force, making it ideal to counter the
weight of the Z -axis table and to reduce the load
on the Z-axis stepper motor.
$5.17 EA, $5.17 TOTAL
P/N 9293K44

DELRIN STRIP

Thin strips of delrin, an engineering-grade

plastic, are used to to reinforce the foamcore in
places where it might dent or wear.
QTY: 20 FT
McMaster-Carr

$0.39 /FT, $7.80 TOTAL

P/N 2638T11

WOODEN DOWELS

If you have the ability to cut them, wooden

dowels are a cheap and effective alternative to
steel dowel pins. Purchase at least 18 of both
1/4 and 1/2 diameter wooden dowel.
~$3.00 TOTAL

Local Art Supply Store

Any color will do. This flexible and somwhat

stretchy tape will be used to couple the motors to
the aluminum shafts, as well as to insulate wiring
connections.

POLYESTER TAPE

I really like this plastic-backed adhesive tape, but

you could get by with masking tape or clear tape.
It is used as a general tape wherever necessary.
QTY: 1 ROLL
McMaster-Carr

$6.81 /ROLL, $6.81 TOTAL

P/N 7630A42

FOAMCORE!

Youll need a 40 x 30 sheet of 1/2 thick

foamcore, and a 30 x 20 sheet of 1/4 thick
foamcore. Several smaller sheets can be used
instead of a big sheet - check the cut patterns.
~$13.00

Local Art Store

STUBBY STEEL DOWEL PINS*

ALUMINUM SPACER

QTY: 2 PACKS (20)

McMaster-Carr

QTY: 3
McMaster-Carr

These pins will get the job done, but are

expensive so search for alternatives first. If you
cant use wooden dowels, youll need to find or
create cylinders which are 1/2 dia. and 1 long.

The motion system of the machine relies on what

is called the capstan effect. This fine braided
steel cable will prevent the aluminum shafts from
spinning without also rolling.

NYLON BUSHINGS

Molded plastic sleeves which are designed to

slide on precision shafts. They provide a
low-friction bearing for the moving parts of the
machine. 1/2 inner diameter.

OR

SHEET 2/15

$6.65/PK, $13.30 TOTAL

P/N 98381A710

These spacers coincidentally have the right

inner and outer diameters to adapt the 5mm
motor shaft to the 1/2 aluminum shafts.

SLENDER STEEL DOWEL PINS*

SUPERGLUE*

QTY: 1 PACK
McMaster-Carr

Local Hardware Store

These pins will get the job done, but are

expensive so search for alternatives first. If you
cant use wooden dowels, youll need to find or
create cylinders which are 1/4 dia. and 2 long.
$8.85/PK, $8.85 TOTAL
P/N 90145A549

$1.54 EA, $4.62 TOTAL

P/N 92510A745

Any super glue will do, although the thinner the

better. I use this awesome 5cP glue, but 100cP
would be OK too. (cP is a measure of fluid
viscocity.)

HOSE CLAMPS

Typically used to secure hoses to fittings, we will

use hose clamps as simple tensioning mechanisms for the steel cables.
QTY: 1 PK
McMaster-Carr

TOTAL MATERIAL COST: $119.74

$7.01/PK, $7.01 TOTAL

P/N 5388K22

STEPPER MOTORS

These easily controlled motors will move the

toolhead around with some degree of precision.
The type depends on your controller, but I will be
using unipolar motors with a step angle of 0.9.
QTY: 3
Alltronics

ILAN E. MOYER

$6.95 EA, $20.85 TOTAL

P/N 28M053

* These are either household items or alternative parts

and are not included in the calculated parts price.

066 FOAMCORE CNC: VISUAL BILL OF MATERIALS (BOM)

3/17/2011

Your Order

3/20/11 7:39 PM

Date
Purchase order
Order created by

March 20, 2011

Ilan Moyer (imoyer@mit.edu)

Ship to
3 Ames Street
East Campus, #358
Cambridge, MA 02142

Send invoice to
imoyer@mit.edu
Payment method

Attention: Ilan Moyer

Shipping method
Ground

Line

Quantity

Item

Ships

Unit price

Total

3 each

1031K14

Precision Ceramic-Coated Aluminum Shaft 1/2" Diameter,

15" Length

Monday morning

$9.00 each

27.00

2 packs

6389K623

Nylon Bearing Flanged, for 1/2" Shaft Dia, 5/8" OD, 1/2"
Length, packs of 5

Monday morning

$3.15 pack

6.30

1 each

9293K44

Stainless Steel Constant-Force Spring 4000 Cycle Life,

.005" Thick, 17" L, .312" Wide

Monday morning

$5.17 each

5.17

20 ft.

2638T11

Black Delrin Strip .020" Thick, 1" Width

Monday morning

$.39 ft.

7.80

2 packs

98381A710

Alloy Steel Dowel Pin 1/2" Diameter, 3/4" Length, packs

of 10

Monday morning

$6.65 pack

13.30

1 pack

5388K22

Worm-Drive Hose Clamp W/Zinc Pltd Steel Screw 11/16"

to 1-1/4" Clamp Dia Range, 5/16" Band Width, packs of
10

Monday morning

$7.01 pack

7.01

25 ft.

8930T22

Commercial Grade Nylon-Coated SS Wire Rope 7X7

Strand Core, .018" - .024", 40# Break Strg

Monday morning

$.41 ft.

10.25

1 roll

76405A13

Masking Tape - Adhesive on Both Sides for General

Purpose, 1" Wide X 36 Yards Long

Monday morning

$7.93 roll

7.93

1 roll

7630A42

High-Temp Polyester Masking Tape 1" Wide X 18 Yards

Long

Monday morning

$6.81 roll

6.81

10

3 each

92510A745

Aluminum Unthreaded Round Spacer 1/2" OD, 1/2"

Length, #10 Screw Size

Monday morning

$1.54 each

4.62

11

1 pack

90145A549

18-8 Stainless Steel Dowel Pin 1/4" Diameter, 2" Length,

packs of 10

Monday morning

$8.85 pack

8.85

Merchandise total

$105.04

Applicable shipping charges and tax will be added.

Phone (609) 689 -3000

Fax (609) 259 -3575

Internet www.mcmaster.com

Email nj.sales@mcmaster.com

http://www.mcmaster.com/OrdPad/OrdPadPrt.aspx?ordid=842514571442&time=1300664355278

Page 1 of 1

SHEET 3/15

14 1/2

13

2 1/4

1 1/2

12 1/4

MATERIAL: 1/2 FOAMCORE

0
1 1/2
2 1/4

NOTE: SAVE THIS INTERIOR PIECE BECAUSE IT

BECOMES THE MACHINES WORK TABLE.

12 1/4
13
14 1/2

ILAN E. MOYER

SKETCH LINE
CUT LINE
066 FOAMCORE CNC: TOP PLATE AND TABLE CUT PATTERN

3/12/2011

MATERIAL: 1/2 FOAMCORE

SHEET 4/15

14 1/2
14 1/8
13 7/8
13 1/2

11

10

8 1/2

7 3/4
7 1/2
7
6 3/4

4 1/2

3 1/2

1
5/8
3 8
/
0
0

3/16
3/4

1
1 1/8
1 3/4

11 3/4
12 1/2
13 1/2

ILAN E. MOYER

SKETCH LINE
CUT LINE
066 FOAMCORE CNC: BACK PLATE CUT PATTERN

3/12/2011

SHEET 5/15

13

1 1/2

14 1/2

MATERIAL: 1/2 FOAMCORE

0
1 1/2

13
14 1/2

ILAN E. MOYER

SKETCH LINE
CUT LINE
066 FOAMCORE CNC: BOTTOM PLATE CUT PATTERN

3/12/2011

WIDE LEG

SHEET 6/15

13 1/2

3
/
16

MATERIAL: 3/16 FOAMCORE

3/8

QTY 2

5/8

1 11/16
13 1/2

3
/
16

NARROW LEG

1 1/2
5/8

QTY 4

3/8

9 3/8

TILING PATTERN

7 11/16

6
4 1/2
3
1 1/2

SKETCH LINE
CUT LINE

0
ILAN E. MOYER

066 FOAMCORE CNC: LEGS CUT PATTERN

3/12/2011

11 1/2

TOP PLATE LARGE STRIPS

1 1/2

SPLIT
QTY 2

1/2

1/2

FULL
QTY 2

11
10 3/4

TOP PLATE
EDGE STRIPS
QTY 4

TOP PLATE SMALL STRIPS

0
1/2
1
1
1/2

BACK PLATE
EDGE STRIPS
QTY 6

SPLIT
QTY 2
FULL
QTY 2

Total split length is the total length of

1 wide delrin strip which needs to be
halved along its length. Total full length
is the total length of delrin strip which will
retain its original width of 1.

ILAN E. MOYER

BACK PLATE STRIPS

10

TOTAL SPLIT LENGTH: 73.5

TOTAL FULL LENGTH: 125
OVERALL LENGTH: 198.5

SHEET 7/15

SPLIT
QTY 2

1/2

FULL
QTY 8

066 FOAMCORE CNC: DELRIN STRIPS CUT PATTERN

SCORE LINE
CUT LINE
3/18/2011

SHEET 8/15
TOP PLATE
EDGE STRIP

TOP PLATE
EDGE STRIP

TOP PLATE LARGE STRIP - SPLIT

TOP PLATE LARGE STRIP - FULL

TOP PLATE SMALL STRIP - SPLIT

FRONT OF MACHINE

BACK OF MACHINE
TOP PLATE
EDGE STRIP

TOP PLATE LARGE STRIP - SPLIT

TOP PLATE
EDGE STRIP

NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16.
ILAN E. MOYER

066 FOAMCORE CNC: TOP PLATE DELRIN STRIP PLACEMENT - OUTSIDE SURFACE

3/19/2011

SHEET 9/15
TOP PLATE
EDGE STRIP

3/16

3/16

TOP PLATE SMALL STRIP - FULL

TOP PLATE
EDGE STRIP

FRONT OF MACHINE

1/2

TOP PLATE
EDGE STRIP

TOP PLATE SMALL STRIP - SPLIT

TOP PLATE SMALL STRIP - SPLIT

3/16

BACK OF MACHINE
TOP PLATE SMALL STRIP - FULL

TOP PLATE
EDGE STRIP

NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16.
ILAN E. MOYER

066 FOAMCORE CNC: TOP PLATE DELRIN STRIP PLACEMENT - INSIDE SURFACE

3/19/2011

SHEET 10/15
BACK PLATE
EDGE STRIP

BOTTOM OF MACHINE

BACK PLATE
EDGE STRIP

BACK PLATE STRIP - SPLIT

BACK PLATE STRIP - FULL

BACK PLATE STRIP - SPLIT

BACK PLATE STRIP - FULL

TOP OF MACHINE

BACK PLATE
EDGE STRIP

BACK PLATE
EDGE STRIP

BACK PLATE
EDGE STRIP

BACK PLATE
EDGE STRIP

NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16.
ILAN E. MOYER

066 FOAMCORE CNC: BACK PLATE DELRIN STRIP PLACEMENT - INSIDE SURFACE

3/19/2011

SHEET 11/15
BACK PLATE
EDGE STRIP

TOP OF MACHINE

ILAN E. MOYER

BACK PLATE STRIP - FULL

BACK PLATE STRIP - FULL

BACK PLATE
EDGE STRIP

BACK PLATE STRIP - FULL

BACK PLATE STRIP - FULL

BACK PLATE STRIP - FULL

BACK PLATE STRIP - FULL

BACK PLATE
EDGE STRIP

BACK PLATE
EDGE STRIP

BACK PLATE
EDGE STRIP

BOTTOM OF MACHINE

066 FOAMCORE CNC: BACK PLATE DELRIN STRIP PLACEMENT - OUTSIDE SURFACE

BACK PLATE
EDGE STRIP

3/19/2011

SHEET 12/15
NARROW
LEG

NARROW
LEG

WIDE
LEG

WIDE
LEG

FRONT OF MACHINE

FRON

T OF

MACH
IN

TOP VIEW

BACK OF MACHINE
BACK PLATE

1/2
BAC

KO

FM
ACH
I

NE

ILAN E. MOYER

NARROW
LEG

066 FOAMCORE CNC: STRUCTURAL ASSEMBLY GUIDE

1/2

NARROW
LEG

3/19/2011

SHEET 13/15

MATERIAL: 3/16 FOAMCORE

13

2 1/4
2

3/4

0
0

1/4
1/2

2
3

5/8

4
5

QTY 2

SKETCH LINE
CUT LINE
ILAN E. MOYER

066 FOAMCORE CNC: TABLE STRUT CUT PATTERN

3/12/2011

MADE FROM DELRIN STRIP

MADE FROM 3/16 FOAMCORE

QTY 2

3
QTY 4
1/2

LAMINATED WITH ADHESIVE

QTY 3

1/2

1/2

11/4

QTY 2

2
QTY 1

3/16

UNLAMINATED

3/16

SHEET 14/15

11/4
CUT LINE

ILAN E. MOYER

066 FOAMCORE CNC: Counter Spring and Table Miscellaneous Pieces

3/20/2011

SHEET 15/15

1 7/16

3/4

1 1/2

0
NOTE: IF POSSIBLE USE A FACTORY-CUT EDGE OF
THE FOAMCORE SHEET FOR THIS SURFACE.

1 7/16
1 11/16
1 1/8

2 5/16

4
BACK PLATE
MATERIAL: 3/16 FOAMCORE
QTY 3

SIDE PLATE
MATERIAL: 1/2 FOAMCORE
QTY 6
3/4

1/2

BEARING STRIPS
MATERIAL: DELRIN STRIP, LAMINATED WITH ADHESIVE
QTY 12
ILAN E. MOYER

066 FOAMCORE CNC: STEPPER MOTOR MOUNTS

SKETCH LINE
CUT LINE
3/20/2011