Basic Vacuum Forming and Vacuum Machine Building

'What is - and how to vac form? The info is not specific to Classic Cylon Centurions, but SURE can be helpful for them and many, many others projects. Here you'll find various threads with great info from our members for the hobby of costuming.
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Spectre » Sat Jul 09, 2011 2:05 pm

WOW--Go go go Big Al! This thread rocks! Keep 'em coming...


Oh, FRACK! But I didn't say frack, I said the Queen Mother of all dirty words! The F, dash, dash, dash, dash word!
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Sat Jul 09, 2011 3:46 pm

:cylongold: Misc. Power Carving Tools

I didn't want this article to get bogged down on something that was off topic and I know it seems I went in another direction with the Foam and the tools but as I thought about it, all of these topics are relative to vacuum forming.

When you search for information on vacuum forming, you will find that it only deals with the actual vacuum forming and not the rest of the steps to get you to a finished part.

Foam and wood is used for many things and many different processes and is always treated as a seperate subject.

Resin Casting is also treated as a seperate subject yet there are guy's right here on the BYC forums that are using resin casting for Cylon insignia parts.

Depending on the piece, Sometimes I use Resin Casting to make Plugs for Vacuum forming. (Excellent Material)
These are some examples I found to illustrate the different parts you can make.

[attachment=1]Resin cast Examples.jpg[/attachment]


Each subject has a bench mark purpose such as Resin Casting is mainly used to create parts for minature models and dioramas. I am not saying that it isn't used for many other things but that is it's bench mark and the primary marketing target for the manufaturers is sometimes completely different from what we might use it for.

The process of Resin casting is a process all in it's own and involves building molds, silicone rubber, Vacuum chambers, and vibration tables. It's a stand alone subject, But also integrated into Vacuum Forming so I will include it and cover the process in a future post.

Blue and Pink Foam is marketed for use as insulation for buildings. and so on.

To me, all of these subjects are relative to vacuum forming. Foam and wood use, Tools, Resin Casting , Carving, Scrolling, and even fiberglassing and vacuum Bagging in some cases!

You use all of these things to get to a finished part.

The same can be said for the tools you need to achive that final product. Featured articals, books, and blogs will talk about Hot Wire but not the sanding and carving tools to make the plugs.

Plug making is discussed on Fiberglassing forums but not so much on Hot Wire topics and Vacuum Forming threads.

Sometimes you want to use a fiberglass part to to make a master and sometimes you want to use fiberglass to put a finish on a plug.

Depending on what you are doing, You may make a foam plug as a master to make a mold from fiberglass, then use the mold to make a fiberglass part, then vacuum bag the fiberglass part to get your desired finished, then use that finished fiberglass part in your vacuum form machine to make a light weight ABS finished part!

I needed to include these tools and materials because I use them and they are great for making parts of any kind.
Like any of the tools I recommend, they are not necessary and you can get by without them but it makes life alot easier.


:cylon: Dremel Rotory Tool

The Dremel is by far the most versitile tool you will ever use! :salute:
Sanding, Carving, Grinding, Cutting, Polishing...This tool can do it all!
As this is the section that deals with the tools for shaping and carving Wood and Foam, I will keep it limited to carving and sanding.

[attachment=7]dremel_foto.jpg[/attachment]

The dremel rotory tool is the most dynamic multi purpose tool you can buy.
For carving wood and foam, it's great! They have a variable speed control and are designed to grip and use in a pencil like fashion.
Dental students use them when the practice because a Dremel works just like the air drill they use in a Dental office. Dremels use same bits, the only difference is a dental air drill is well,... air driven and air drills are capable of much higher speeds.
These are carbide cutters and you can get them in all shapes and sizes.

[attachment=0]tungsten_carbide_burrs_prd0_jpg_thumb-250x252-fit_jpeg_thumb-250x252-fit.jpg[/attachment]

These are Tungsten Carbide Grinders.

[attachment=6]Tungsten+Carbide+grinder2.jpg[/attachment]

Dremel tools and bits can be found almost everywhere, Home centers, Hardware Stores, Hobby Stores, On Line...etc
I can say I use my Dremel more than any other tool I own. Ok Nuff Said! :wink:


:cylon: Power Carver

This is a tool made by Proxxon Tools
and it looks like a rotory tool but is actualy a recipricating carving tool.

[attachment=5]Proxxon Power Carver.jpg[/attachment]

This tool work great for carving wood and foam with little effort.

You can purchase gouging blade sets for this tool giving you a great variety of widths and shapes.


Here is a set from Packard Wood Works
and is a great selection of bits.

[attachment=4]FlexCutGroup-carving tools.jpg[/attachment]


This next tool is from Proxxon Tools
and could have been included earlier with the power sanders, but I feel this tool is more suited to carving rather than sanding. It is certainly a sanding tool but I find that it's purpose is utilized more for carving.

[attachment=3]Proxxon Hand held belt sander1.jpg[/attachment]

[attachment=2]Proxxon-Hand-Held-Belt-Sander.jpg[/attachment]

This tool is excellent for many materials and is a great addition to any tool arsenal.
The angle of the head is adjustable and the belts come in many grits.


Next Up: Hot Knives

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Last edited by Big Al on Sat Aug 13, 2011 12:05 am, edited 3 times in total.
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by GoldCylon » Sat Jul 09, 2011 4:42 pm

I'd love to get a hand held belt sander. They look great for some of the detailing out.

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Basic Vacuum Forming and Vacuum Machine Building

Post by Skullbeast » Sat Jul 09, 2011 5:51 pm

I got an electric hand held 1/2 belt sander from harbor freight for 30 bucks. They call it a file. It's making these guns a snap.

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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by GoldCylon » Sat Jul 09, 2011 6:05 pm

I'll be in LA on Thursday, Friday, and Saturday on July 21st. Lets see what we can exchange when I arrive.

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Basic Vacuum Forming and Vacuum Machine Building

Post by Skullbeast » Sat Jul 09, 2011 7:29 pm

Sounds cool that just so happens to be my sons first birthday weekend with out of state inlaws and all. But I should still have some time.

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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Sat Jul 09, 2011 7:35 pm

:cylon: I agree these are awsome sanders and I have first hand experience with the proxxon. I worked at a Hobby shop for 5 years and we sold proxxon so I have used all of the proxxon tools, Didn't own em just used them at the store.

I think originaly they were an air tool used in car body work and then they made these models electric. I could be wrong?


Here are some other brands
This one is a portagrind

[attachment=2]portagrind.jpg[/attachment]

Here's the link

PortaGrind


This is the harbor freight one, Good Tip! Awsome price!

[attachment=1]Horbor Sander.jpg[/attachment]

Here's the Link and only $34.00 Bucks!

Harbor Freight


I checked Sears no craftsman, but they carry the Proxxon and the milwaukee
a little pricey over Over $200

[attachment=0]Milwakee_belt.jpg[/attachment]

Here's the link

Sears


I'm sure there is more but the Harbor freight model looks great.!
I have bought many import tools from HF because if I waited to buy the name brand tools, I wouldn't have a shop! :D

Thank the stars for Chineese Imports!
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Last edited by Big Al on Sat Aug 13, 2011 12:06 am, edited 2 times in total.
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Sun Jul 10, 2011 1:09 am

:cylongold: DIY Power Cutting (Carving) Tools

:cylon: Just like everything else, you can buy one, or make your own.
These are some examples of how you can make your own hand held cutters from stuff you may already have or stuff you can get for next to nothing.

I showed you the commercial hand cutters in a prior post. so these are cutters that others have made and shared.
These cutters are made from Soldering guns. You can find this one here at Club Cycom

:cylon: Small Hoop and Gun

[attachment=8]smallloopandgun1024.jpg[/attachment]


These next cutters are featured a Horror Seek Dot Com a great site with lots of information

:cylon: Knife Blade Cutter

[attachment=7]KnifeBlade_tool.jpg[/attachment]

:cylon: Coping Saw made with a rolodex file hanger

[attachment=6]Coping Saw.jpg[/attachment]

:cylon: Puck Cutter

[attachment=5]Puck Cutter.jpg[/attachment]

[attachment=4]Puck cutter Side.jpg[/attachment]

:cylon: Edge Routing Tool

[attachment=3]Edger Cutter Alone.jpg[/attachment]

[attachment=2]Edger Cutter On Foam.jpg[/attachment]

[attachment=1]EdgerCutting.jpg[/attachment]

All of these can be found at Horror Seek Dot Com


This one is from Terra Genisis

:cylon:U Shaped Cutter

[attachment=0]U shape cutter.jpg[/attachment]


Up Next: Hot Knifes

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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Sun Jul 10, 2011 11:08 am

:cylongold: Hot Knives

Ok This will be quick. DIY hot knives are not to common. and most pro knives start at $150 up. :wtf:

So I'm not going to list all the different kinds just a few I thought were good.

The first is from one of my favorite tool outlets Harbor Freight

[attachment=8]Harbor Freight Knife.jpg[/attachment]

This one comes in at around $20.00


This one is made by Dremel and is available at Tower Hobbies and comes in at around $50.00 Everybody recognizes this one. It doubles as a wood burner

:cylon: Dremel Hot Knife

[attachment=7]Dremel Hot Knife2.jpg[/attachment]


This one comes in around $60 to $70 and is a good looking carving knive and you can get this here at TL Marshal Company

:cylon: Crafters Hot Knife

[attachment=6]HW-1600-Crafters-Hot-Knife.jpg[/attachment]


This is a 3 Pc. sled set but is spendy and comes in at $360.00 also from TL Marshal

:cylon: Craftsman Hot Knife Sled

[attachment=5]Craftsman Hot Knife Sled 2.jpg[/attachment]

:cylon: Craftsman Hot Knife Sled

[attachment=4]Craftsman Hot Knife sled 1.jpg[/attachment]


Here are some knives that I thought were unique and are used to cut Nylon webing material
I only found One site for these and no priceing. so I think they are an industrial product available from this company Lyteze Products located in the UK.

:cylon: Mark 5

[attachment=3]mark5 Hot Knife.jpg[/attachment]

:cylon: Mark 2

[attachment=2]Mark2.jpg[/attachment]

:cylon: Mark 4

[attachment=1]mark4.jpg[/attachment]

:cylon: Mark 5

[attachment=0]mark5a.jpg[/attachment]

These are very cool but I'll bet they are real spendy? :huh:

Ok Thats it for the knives.


Next Up: DIY CNC Hot Cutters, DIY CNC Routers and DIY CNC Laser Plotters (Routers) :cool: (These are very cool) :cool:

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Last edited by Big Al on Sat Aug 13, 2011 12:10 am, edited 2 times in total.
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Sun Jul 10, 2011 11:11 pm

:cylongold: I Found a PDF Plan for the DIY Hot wire Scroll with Tilt Table


This is one of my favorite Home brew Tables and I mentioned it in a previous post. If you wanted to build a really nice med size table, this would be the one.

:cylon: Cutter With Tilt Table

[attachment=2]Cutter w tilt table.jpg[/attachment]

:cylon: Cutter With Tilt Table

[attachment=1]Cutter w table.jpg[/attachment]


Very Nice Plans with all the measurements.

:cylon: Here Is the PDF Plan.

[attachment=0]DIY Foam Cutter Plans.pdf[/attachment]

:cylon: Here is a link to a Build of this Tilt Table Build


Here's a Video animation




Here's Another Video





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DIY Foam Cutter Plans.pdf
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Wed Jul 13, 2011 10:47 pm

:cylongold: DIY CNC Hot Wire Cutters,

:cylongold: DIY CNC Mills (Routers) and

:cylongold: DIY Laser Plotters


Ok these are the Fracking Felgercarb! Home Made CNC machines for making anything you want!
2D pieces 3D pieces, Foam, Wood, or any other material that you can Melt, Carve or Cut.

I'm Starting with the CNC Hot Wire Foam machine and then we will cover the router mills and then the laser plotters which are basically the same machine as a mill except with a laser cutting head.

I have not built one of these yet but the plan was on my table when I had to close my shop and take care of my dad. So Here's what I know and the links.

You don't have to go this far, but if you are a modeler like me, you will end up here.

DIY Home Made CNC Machines were unheard of a few years ago and if you wanted something made from a CNC machine you had to take your project to a machine shop and pay through the nose to get a part made on a machine that cost thousands!

Now you can make your own CNC machine from an inexpensive computer and materials from a home center.

Stepper motors and control boards are easy to get, software is abundant and before you know it, your cutting Plugs to near perfection!

I have spent the last few days collecting information and links on this subject and I hope you like it!

Not only can you make your plugs for vacuum forming parts but you can make damn near anything!

Just Like foam, this subject is a stand alone topic however this is still about achieving Vacuum Formed parts so I will try not to drift away to far and will write about this subject with making foam and wood plugs in mind.


:cylon: This first Machine is the one that got my attention.

[attachment=9]DIY CNC Hot wire.jpg[/attachment]

It can be found Here at 8 Linx with all of the building details.
This site is packed with photos, plans, and links for parts and material sources other CNC projects, Forums and blogs about home made CNC Machines etc.


This is a commercially made Kit and the design is based on the Foamlinx FC912 Design.

:cylon: Foamlinx FC912

[attachment=8]4_axis_cnc_foam_cutter_hot_wire_machine_mid.jpg[/attachment]

These are kits made by RC Foamcutters
and are awsome machines they make 5 different kits from basic to pro starting at $299 for basic to $2500 for the whole schmoo!

This is a Price List
that compares all the kits, there contents and the pricing.

This is a great way to go when your building one of these machines.
This company's Pro kit has everything! for $2500 and is a great concideration if you have the means, To compare where the pricing lies building a kit is about half of what a commercialy built machine of the same size would be around $5000 to start.

If you want to scratch build one it gets alot cheaper. :wink:
These are some examples of other hobbyist that have built the 8Linx machine

:cylon: Glenn Corrie Machine

[attachment=7]Glenn Corrie Machine.jpg[/attachment]

:cylon: Maker Unknown

[attachment=6]Maker Unknown.jpg[/attachment]

:cylon: Vern's Machine

[attachment=5]Vern's machine.jpg[/attachment]

:cylon: Ron Kruze Machine

[attachment=4]Ron Kruze Machine.jpg[/attachment]

:cylon: Maker Unkown

[attachment=3]3920-work-bench.jpg[/attachment]

:cylon: This one is made from wood or MDF! :salute:

[attachment=2]CNC 1.jpg[/attachment]


This company, Dray Construction sells plans for this wood made design for $9.99

[attachment=1]Wood Made CNC Hot Wire.jpg[/attachment]


Here is another Wood built CNC hot cutter project from CNCRO
and is a photo essay build with great detail, parts list and lots of detailed photos for the build.

[attachment=0]Wood cnc-foam-cutter.jpg[/attachment]

All Fracking Awsome machines and they will make precision parts and plugs! :salute:

You don't have to go this far to make plugs or parts, but is a very cool way to go.

More to come

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Last edited by Big Al on Sat Aug 13, 2011 12:13 am, edited 2 times in total.
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Thu Jul 14, 2011 3:58 am

:cylongold: 3D Cutting and Turntables

3D Parts can be made many ways, one way is with a turntable
Adding a turn table takes you to the next level even when working with a stationary scroll table.

A turn Table can be a simple "Lazy Susan" Style and you can spin it by hand when working with a stationary scroll cutter, or can be integrated into your CNC hot Cutter.

It can also be built like a potters wheel, or can just be one speed.

Here are some Turntables

:cylon: This is a Home made machine making a 3d nose for a foam Mig 3
Cylon Arm and Leg Sleeves could be made the same way




:cylon: Here is a 3D demonstration using a turn table



Here are some Turntables some commercial others home brew

:cylon: This one is made by Foam Plotter

[attachment=7]Turn Table.jpg[/attachment]

Here is there link but I didn't see any pricing I'll bet there spendy
Foam Plotter.eu

here are some home brew tables

This is a wood built rotory turntable
[attachment=5]Rotary-turntable-3806.jpg[/attachment]

This one was made for a controled cnc cutter
[attachment=6]eps_foam_base_cap_cutter_1s.jpg[/attachment]
[attachment=4]eps_foam_base_cap_cutter_7s.jpg[/attachment]
[attachment=3]eps_foam_base_cap_cutter_8s.jpg[/attachment]

This is a stiff wire and arm set up with a turntable
[attachment=2]3D Turntable.jpg[/attachment]

Here is a lathe set up
[attachment=1]3D Turntable2.jpg[/attachment]


I'm Pretty sure these were made with a cnc cutter
[attachment=0]Blue Foam helmets.jpg[/attachment]

More to come
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Thu Jul 14, 2011 5:07 am

:cylongold: DIY CNC Mills (Routers)

CNC Mills are just as cool as the CNC Hot wire machines! :cool:
It's my opinion that the CNC Mill goes hand in hand with CNC Hot Wire machine and all of the other machines I have covered.

CNC Mills can carve 3D parts from foam and wood with a router or rotory tool head or cutting laser attached to a cnc table.

These are some examples and video of home made CNC Mills and the relative links.

These machines are very inexpensive and are precision.


Here is a CNC Mill Demo
Imagine the plugs you can make with a machine like this :blink:




This machine is a table top CNC mill designed by Max Ratner who is a Engineering student at the San Jose State University.

Mr. Ratner has an Associate
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Last edited by Big Al on Sat Aug 13, 2011 12:19 am, edited 2 times in total.
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Thu Jul 14, 2011 12:37 pm

:cylongold: DIY CNC Mills (Routers) Cont.

This is the Slosylva 25 x 25 Dual Leadscrew Machine

:cylon: 25x25 Closed Front

[attachment=0]25x25_CNC_closed_front.jpg[/attachment]


This is the machine built from wood

:cylon: 1x4 Wood CNC Machine

[attachment=8]1x4_cnc_wood.jpg[/attachment]


:cylon: The Basic Top 25x25

[attachment=9]25x25_basic.jpg[/attachment]


:cylon: Table Folds for storage

[attachment=1]25x25_CNC_folded.jpg[/attachment]


This is their 13x13 Fixed Gentry Machine

:cylon: 13x13 Fixed Genrty
[attachment=7]13x13 fixedgantry.jpg[/attachment]

This is the machine Built from wood

:cylon: 13x13 Fixed Gentry Wood Machine

[attachment=6]13x13wood1.jpg[/attachment]

Same machine built from Metal and composite parts

:cylon: 13x13 Alternate Build

[attachment=5]13x13alt1.jpg[/attachment]


This is Solsylva's 24 x 48 Rack and Pinion, or Leadscrew Machine

:cylon: 24x48 Rack and Pinion

[attachment=4]24x48 rack_pinion_CNC2.jpg[/attachment]

Same machine built with wooden rack

:cylon: 24x48 Wood Rack

[attachment=3]24x48 cnc_Wood rack.jpg[/attachment]

This is a great site with lots of info, Inexspensive plans, and lots of downloads and links for supporting parts.
Solsylva CNC Plans


This is another one I found on Inscructables The DIYLILCNC Open Source plans for a very nice machine.
[attachment=2]The-DIYLILCNC-Open-Source-Plans-For-a-Low-Cost-E.jpg[/attachment]

More to come


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Last edited by Big Al on Sat Aug 13, 2011 12:21 am, edited 3 times in total.
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Big Al
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Fri Jul 15, 2011 1:31 am

:cylongold: Laser Cutters/Plotters/Engravers

Laser Cutters are just like printers or plotters with a laser head instead of an ink head or plotter pen.

Instead of using paper sheets, you load them with sheets of wood, Plastic, foam, or leather and instead of printing with ink, they cut or engrave the material with a laser.

A Laser machine can not cut metal because of the lower power but can engrave aluminium.

These machines are part of the CNC machine family and are awsome part makers. Down side is that these machines can get pricy real quick!

The more powerful your laser the more money it will cost.

Laser cutters usually cut med to thin flat material, the thicker the material, the more laser power you need.

I wanted to throw this one in because these are used in model airplane kit manufacturing.

To keep it short, when you learn how to build wood airplanes, you start with a kit, I started with a Gillows kit, it comes with plans and an assortment of balsa wood sufficiant enough to build the plane. The wing ribs and fusalage formers, are printed on sheets of balsa and you cut the parts out by hand, Clean sand and final shaping before glueing.

:cylon: Hand Cut Parts

[attachment=5]IMG_0014.jpg[/attachment]

Bigger more advanced kit makers started making their kits with die cut parts. The problem with die cut parts is that when a production run starts, the parts are clean cut and very little cleaning, shaping or sanding is necessary, After a few hundred production runs the dies become dull and the process becomes Die Mashing instead of die cutting. So die cutting is better, but cleaning and final shaping still needed.

Now kit makers and modelers alike are making their parts with CNC Laser Cutters!

This is the ultimate cut for wood parts of this nature. Parts are presision perfect right from the board.


:cylon: Here is a demo of a laser cutter making Wing Ribs and tips.




You can make 3D parts from flat stacked parts
Here is an example of a flat stack build up to make a wheel pant for an airplane.

:cylon: Wheel Pants

[attachment=4]Wheel_pants.jpg[/attachment]

This can be filled, sanded and shaped and can either be used directly on the airplane or made it into a plug.


Here is a 3D camera project from flat cut parts

:cylon: Flat Cut Parts Sheet

[attachment=7]070711_rg_DIYLaserCutCamera_02.jpg[/attachment]

:cylon: Camera Build

[attachment=6]070711_rg_DIYLaserCutCamera_01.jpg[/attachment]


You can purchase this commercial model from Emission Technologies
for a cool $19,000,00 :wtf: OR........You can build your own! :smile:

:cylon: Commercial Laser Cutter

[attachment=1]Commercial Laser Cutter Engraver.jpg[/attachment]

You can buy these machines with laser powers of 70,100,130 and 150 watts.
or Here are the Plans Emission Technologies sells for a Build it Yourself Co2 Laser machine


Here is a DIY CNC Laser Cutter Machine build site for a cutter similar to the commercial machine above.

:cylon: DIY CNC Laser Cutter

[attachment=0]DIY Laser Cutter.jpg[/attachment]

Here is the link where you will find this project with detailed downloadable PDF bluprints of this build.

They also sell Parts Kits for the various sections of the build.


Here is a machine build essay DIY How to build a homemade Router Laser CNC that looks great! Lots of step by step pics of the build and recommendations and resource links.

:cylon: Laser Cutter 3

[attachment=3]Laser Cutter 3.jpg[/attachment]


This is the machine in action



Laser Cutters can also be custom made from Plotters, and old Printers and can save alot of time building the X,Y Carriages.


Here is one of 4 books recommended by this site.
Looks like a good one.

CNC Robotics

:cylon: CNC Robotics
[attachment=2]CNC Robotics.jpg[/attachment]

More to come

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Last edited by Big Al on Sat Aug 13, 2011 12:22 am, edited 3 times in total.
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