Overall WorkflowLike laser cutting, vector-based 2D drawings are used to define where the machine will cut. The depth of the cut is specified in the Zund software and can be assigned to geometry by layer. There are several different types of tools that can be used with the Zund Cutting System. The GSD has the following options available:
Universal Drawing Tool (UDT) - For drawing lines with a pen. Universal Cutting Tool (UCT) - For most cutting operations Electric Oscillating Tool (EOT) - For soft materials such as cardboard, foamcore, or rubber. Pneumatic Oscillating Tool (POT) - like EOT but with greater blade throw and faster oscillation for thicker materials. Driven Rotary Tool (DRT) - For fabrics and fabric-like materials. A variety of knives are available for each tool, but material presets are generally configured to make knife changes extremely rare. Only TA's may change out knives. Router Module (RMA) - For 2.5D milling of aluminum, thick plastics and other rigid board materials. The router has the following tools available: R-118A: .236"⌀ x 1.06" routing depth (for foam) R-133A: .1186"⌀ x .433" routing depth (for down-cutting wood products, hard foam) R-136A: .236"⌀ x .866" routing depth (for down-cutting wood products, hard foam) R-141A: .401"⌀ x .157" routing depth (V-shape bit for chamfering top edges) R-202A : .076"⌀ x .23" routing depth (for plastics, wood, aluminum, laminated aluminum/plastic panels) R-204A : .156"⌀ x .55" routing depth (for plastics, wood, aluminum, laminated aluminum/plastic panels) R-205A: 197"⌀ x .63" routing depth (for plastics, wood, aluminum, laminated aluminum/plastic panels) R-206A : .234"⌀ x .86" routing depth (for plastics, wood, aluminum, laminated aluminum/plastic panels) R-208A : .118"⌀ x .31" routing depth (for laminated aluminum/plastic panels only) P-201A: .217"⌀ x .63" routing depth (for polishing acrylic) E7-A: 60 degree x 4.7 mm routing depth engraving bit E8-A: 40 degree x 7.5 mm routing depth engraving bit
Material type and thickness will inform which of the cutting or engraving tools can be used. Suitable ApplicationsThe Zund is best used for cutting materials that cannot be cut on the laser cutter, such as plastics and synthetic fabrics or foam rubber that release fumes, highly flammable materials like foam-core and cardboard, or cuts in materials that are larger than the size of the laser cutter bed. It may be suitable for routing smaller sheet stock that would be difficult to mount to the CNC routers, as well as materials that might require extra setup on the CNC routers, such as soft metals (aluminum, copper, brass, etc) and thick plastics, such as acrylic or expanded PVC board, but its 3-dimensional capabilities are limited. A secondary benefit of the Zund is that, because it uses blades and does not produce heat like that generated by the laser cutting process, there are no burned edges on materials. The Zund can also be used for more unusual materials for specific projects, such as wax, metal mesh, corrugated plastic, plastic films, fabric, foam and felt. The Zund is NOT to be used for materials that are easily cut on the laser cutter or the CNC's, or simply as a time saving measure, such as foam-core rectangles that could be cut by hand. The Zund cannot handle materials over 1" in most circumstances, and in general cannot do more than 1/2" with most blades. The Zund is NOT primarily a router, and should not be seen as an alternative to the AXYZ or Onsrud routers for milling jobs. The router is only used for projects approved by FabLab staff and performed under their supervision. A full list of usable materials is available through the 'cuttmp' folder on the GSD server. If the intended material is not listed, work with a TA to define a new material process based on similar materials or by working through a series of tests in the material. You will need to supply enough sample material for testing.
Because force is exerted on the material by the blade moving during cutting (unlike the laser cutter), smaller features may not come out as cleanly or detailed as they would on the laser cutter. In general, the Zund is better suited to larger features. For routing, offset for the diameter of the bit does not need to be integrated into the file, the Zund will automatically apply the appropriate offset and route along the outer or inner edge of the specified vector, not down the center. ENGRAVE will cut down the center of both open and closed curves. Route (open and closed curves) will be cut to one side of the curve or the other, using the radius of the tool as the offset. An option in the cut parameters for "inside" or "outside" will control this; watch cut direction in Cut Editor or see the dotted line in Cut Center. AccessStudents are able to make job requests and reserve up to 90 minutes each day through SERVICES, reserving only time that is staffed by TAs. Students may request after-hours time through this system, but that time must be booked by a TA. 180 minute limit for end-of-semester, total usage, in addition to the daily 90-minute limit. TA hours are 8-12 hours each day, 10-10 or 10-6 (Friday and Saturday), or as able to be staffed each semester. File Organization/PrepAccepted File Types: EPS / AI (this is best) DXF (has some issue with curves, possibly the preservation of layer order) HPGL Use layers to organize and assign a machine operation to the geometry. Name the layer to correspond to desired the machine operation. Layer order also determines operation order, use the following order of operations as a guide: Cutting Methods/OperationsCut- V-Cut
- V-Cut is a knife operation that uses the VCT only, with the blade cutting at an angle on both sides of the curve. Angle must be set physically on the tool, as well as specified in Cut Center applications.
- Uses Vectors (open and closed).
- Bevel Cut
- V-Cut is a knife operation that uses the VCT only, with the blade cutting at an angle on one side of the curve. Angle must be set physically on the tool, as well as specified in Cut Center applications.
- Uses Vectors (open and closed)
Correctly set up layers in both Illustrator and Rhino Files should be clean with as few control points as possible. Check file for floating control points or geometry, or unclosed shapes. When converting from Rhino/AutoCAD to Illustrator, ensure the resulting geometry is completely accurate as some changes can occur during export. Line weight and color are not read by the Zund, machining operations are assigned by layer names. If there are multiple layers of the same operation, do not label them Cut 1, Cut 2, etc., simply label all layers by the desired operation and the Zund software will automatically number them in order. Layer AliasesThere are many 'aliases' for each operation, which are the range of acceptable labels that can be interpreted by the Zund. - 'Register' can be labeled as: Camera, Regmark, Regmarks, Dots, Registration, Register, Reg
- 'Draw' can be labeled as: Draw, draw, sharpie, pen, Sharpie, Pen, Lines, lines, line, Line
- 'Score' can be labeled as: Score, score, etch, Etch, cutting
- 'Cut' can be labeled as: Cut, Straight cut, Through cut, Throughcut, CutContour, CutContourFullCut, CutContourFast, CutContourSlow, Thru-cut, cut, thru cut, Thru cut, CUT, cut, cut through, Cut Through, ThruCut, thrucut, cutting
- 'Engrave' can be labeled as: CutContourEngrave, Engrave, engrave, engraving, Engraving
- 'Route' can be labeled as: Router, CutContourRoute, Route, route, router, routing
Import into Cut Editor, Send to QueueImport files into the editor, assign material type, thickness: - Carefully measure the stock with calipers and enter the value in the "Thickness" space near the bottom of the "Select Material and Thickness" window. It is recommended that you do NOT change any other settings, materials or parameters.
- To use the calipers, close the jaws completely and press the power button. If the screen does not read '0.000 in', press 'ZERO' to reset the calipers. Open the jaws using the thumb wheel, then close fully on the edge of the material. Take measurements from several locations on the stock to ensure accuracy. See: Step by Step Tutorial on Using Calipers
- If the desired cutting material is not listed, ask a TA what an appropriately similar material would be, or work with one to define a material process specific to your objective.
Assign methods to geometry.
- Double-click on the layers/methods listed on the right, choose the appropriate method for each.
- Or, select geometry and then right-click and either choose an existing method used in the file, or assign a new method type.
- Order of layers/methods determines cut/operation order that will be performed by the machine.
- Register as the first method
- Geometry on "none" layers/methods will not do anything on the machine
- Cut internal shapes or draw before cutting out larger perimeter pieces.
Save and then send to queue, the file will then appear in the Cut Queue software. Double-click on this job to open the file in Cut Center to assign tools and cutting depths to each method, run test cuts and simulations, and to establish reference locations. HardwareVacuum Hold-DownMaximum cutting size is 98.3"x52.3" Porous cutting area will pull vacuum through and hold down nonporous materials. Can be zoned (runs from front-to-back of machine, starting on right side and moving toward left) to increase hold down in the needed section. Auto-starts at the beginning of jobs, can be set to auto-fit (narrow) to the stock. Best to check hold-down before starting job (turn on vacuum in Cut Center and try to move material) Adjustable strength (1-10, most materials use 5 by default to minimize noise) "Mask"-off areas that aren't used, but within the length of the zone using cardboard or scrap to increase hold down. When cutting porous materials, cover with thin nonporous material such as taffeta. SealgripMust be used when routing or engraving. Be sure that the console display reads 'overlay on' so that the machine knows the sealgrip is being used. CameraUsed for material border and 1/4"-dot registration. If the camera is not picking up the edge of the stock, lighting can be adjusted, as well as brightness/contrast/etc by right clicking on the camera live feed during the registration step. ModulesHold the tools. There are two universal tool holding modules, and one router module that must be attached before routing jobs and removed immediately after. Tool changes are performed by removing and installing desired tools in the tool holder modules. Performing a Tool Change
Universal Drawing Tool (UDT) - For drawing lines with a pen. Useful for labeling parts. Universal Cutting Tool (UCT) - For most cutting operations. Uses a variety of inserts. Does not oscillate, drags blade through material. - V-Cut Tool (VCT) - For cutting angles in soft material. As this tool drags the knife through the material, it is not suitable for very thin material as it lifts the material as it cuts, nor for very thick material, as the material begins to crush rather than cut. 1/8" - 3/18" foam core is a reasonable material range for this tool.
Electric Oscillating Tool (EOT) - For soft materials such as cardboard or foamcore. Good when UCT excessively drags or deforms the material. Pneumatic Oscillating Tool (POT) - like EOT but with greater blade throw. Good with thicker materials that the EOT has trouble cutting cleanly. The POT cuts a little cleaner than the EOT, but because it is pneumatic and runs off the same compressor as the Onsrud and woodshop air hookups, it cannot be used while the others are running. Only use the POT if the Onsrud is not currently operating. Driven Rotary Tool (DRT) - Uses a rotating circular blade. For fabrics and fabric like materials. Minimizes force acting on the material, but has the greatest overcut due to the blade geometry.
Cutters (Knives and Endmills)Many knives are available to insert to the tools, with differing geometry based on the intended purpose. A full list of blades, their geometries, and suggested materials is available at <link to pdf> Console
The console directly controls the cutter without going through the software. The console is used primarily for performing tool changes, turning the machine on/off, and switching between online and offline mode. - The gantry can be manually controlled by the Travel keys, and moved rapidly by holding the Shift key.
- The vacuum can be toggled on and off by pressing the Shift key and the VAC key.
- Pressing any of the Travel keys or STOP during a cutting operation will pause the job and raise the tool until the Online button is pressed, resuming the job.
Light BarriersThe Zund has safety features to prevent injury during operation. The main feature is a series of 'light barriers' that are projected from one end of the gantry to the other, on the front and back side of the cutter. If these beams are broken by someone reaching into the operating area, or if a piece of stock lifts up unexpectedly, the cutter will immediately stop operation. The LCD screen will display that a light barrier has been triggered, and will list what barrier was broken. To continue the operation after everything is cleared from the table, press 'OK' then 'ONLINE' to continue the cut from where it stopped. While the light barriers are a soft stop, the four red emergency stop buttons located on each corner of the machine are a hard stop. When an emergency stop button is pressed, the operation immediately stops, cancels the current job, and disengages the tools. To continue from an emergency stop, the triggered button must be twisted clockwise to release, then the instructions on the LCD must be followed. The tools will re-engage and require re-initialization. The job will have to be restarted from the PC. If something begins to go wrong during the cut, such as the stock moves unexpectedly, the operation can be paused by pressing any of the gray directional buttons on the console, or 'ONLINE'. This takes the machine out of online mode, pauses the operation, and lifts the tool. The cut can be continued by pressing online once the issue is resolved. SoftwareOnline ModeThe Zund has two main modes of operation, online and offline, which are switched between by pressing the red 'ON-LINE' button at the bottom right of the console. Most setup operations are performed in offline mode, such as tool changes, parameter editing, and making changes to the file through either Cut Center or Cut Editor. Online mode is activated before performing any cuts, or entering Interactive Mode through Cut Center. Most common errors occur from not being in the correct mode, but are easily fixed by pressing the button and entering the correct mode. Cut QueueThe Cut Queue lists jobs, both incomplete and completed. Order can be changed by clicking on a heading at the top of the list. We generally sort the list by date, to keep the newest jobs at the top of the queue. Once a job is completed, it will be moved to the 'Job done' queue, under the 'Job queue'. Files can be accessed the same way from either, by double clicking to open directly in Cut Center, or by selecting the 'E' icon to open directly in the Editor. Cut Editor The Cut Editor is used for making changes to the geometry of the file, including adding, deleting, moving and scaling vectors. In addition, the starting point and cut order of individual vectors can be specified if the auto-order the program assigned does not perform satisfactory cuts. BridgingThe Cut Editor is also used to add bridges to routing jobs to ensure the cut out features are not pulled up by the dust extraction, which will ruin the job and risks damage to the bit and router. A routing file before and after bridging. Bridges are formed during the 'Multi pass last depth' parameter in the Cut Center 'Machine step settings' window, and should be .02 at a minimum to ensure strong bridges. Setting order/direction/starting point of a vectorIf a corner or feature of your geometry is getting caught and dragged by the blade, the order and direction of each line can be altered by first selecting the view order and view direction icons. The most common cause of corners being dragged is when the blade approaches an acute angle that has already been cut previously. The tip is unsupported, and if the blade is moving too quickly, it will catch and be dragged along with the blade. This is most damaging in foamcore, where the paper tears away and the foam interior balls up.
Example of a risky cut. Moving from the center-out increases the risk of the edges being torn, and an example of a safer cut, cutting from areas with more mass inwards. Pink arrows denote open contours while the light teal arrow (upper right corner) indicates closed contours. By selecting 'Reverse direction' through Tools --> Reverse direction, the editor enters a mode where every time a line is clicked, its direction reverses, denoted by the small pink arrow at the starting point of the line. This is most useful in situations where the blade approaches thin or acute features and ends up deforming or dragging them. By traveling outwards from the center of mass, the sharp corners are preserved. By selecting 'Interactive order', the order of each line can be set by clicking on each line in the desired order. Adjusting geometry
Precise adjustments to geometry is made using the 'Numerical geometry' window, accessed by highlighting the geometry to be edited and right clicking. Numerical geometry can be used to move, scale, and rotate geometry by specific values. The boxes in the upper right select whether the geometry will be moved/scaled from the center, or a specified corner. Any operation more complex, especially adding geometry, should be performed in the original program, at the Cut Editor lacks most of the features that make changes accurate, such as snap-to fuctionality. FillsWhen using the engraving tool to remove material from within an enclosed area, a toolpath needs to be generated in this area, otherwise the router will only engrave along the perimeter of the shape. There are two methods of filling available, Island fill and Hatch fill. Island fill offsets from the outer border repeatedly until the shape is filled, while Hatch fill creates a series of parallel lines within the border, either horizontally, vertically, or at a specific angle. Bit size and overlap percentage must be set correctly in Cut Editor in order to achieve the desired result when cutting. If a different-sized tool is used to cut the material than is specified when creating the fill in Cut Editor, then damage may be caused to the bit, material may not be completely removed from the area, or too much material will be removed at the perimeter of the area specified. Cut Center The main program used for performing cuts. Cut Center allows for assigning operation methods to layers (steps) if not completed previously, and adjust settings such as which tool and blade are being used. The Cut Center also allows for adjusting offset from the origin, performing test cuts, and adjusting and testing the vacuum.
The main icon toolbar in Cut Center with the most commonly used icons labeled. Some icons, such as 'Interactive Mode' are only available when the machine is in 'Online' mode and will be grayed out unless in the correct mode. To change a layers operation parameters, double click on the layer to open the 'Machine step settings' window. The 'Method' drop down changes machining operation type. The tool and blade drop downs change the tool to be used for the operation from a preset list of available tools. In general there are usually only one or two blades and available tools per method per material, to ensure the best tool is being used. If the tools installed the machine do not match any of the listed tool for the operation, a tool change must be performed. Setting a reference pointWhen not referencing off of the borders of stock or to registration dots, a reference point must be set. Reference points are most often used when using irregular or scrap pieces of stock where there are no clean edges to reference off of and registration dots have not been built into the model. This point can be anywhere on the table, and will move the jobs origin point to the set reference point. To set a reference point: - Check the machine is in 'Online' mode.
- Select the 'Interactive mode' icon.
- Use the arrow keys to navigate the laser pointer over the desired reference point.
- Right click and select 'Set reference point'.
- To ensure the cut will not go off the edge of the material, run a simulation by selecting the 'Simulation' icon and then 'Laserpoint simulation'
- The laser will then trace out every cut that will be performed during the job. Watch to make sure it stays within the boundaries of the stock at all times.
Vacuum settingsThere are two main settings for the vacuum hold down: Vacuum width and vacuum strength. Vacuum strength is specified on a slider from 1-10 by selecting the 'Vacuum strength' icon. Vacuum width is the width of active vacuum hold down along the y axis of the table and is denoted by the dashed yellow line on the screen. Vacuum zones run from the set width on the y axis, starting from the right side, all the way to the back of the table. The vacuum can not be adjusted front to back along the x axis, but unused space should be covered with cardboard or scrap to increase the hold down under the stock. To adjust the width, right click the table and select 'Set vacuum width'. Test the vacuum after adjusting the width to ensure the full width of the stock is held down.
'Machine step settings' windows before assigning an operation, for a Thru-cut operation, and a routing operation. Adjustable operation parameters- Method: The type of operation to be performed. Each material has a set of available operations depending on its characteristics.
- Name: What the layer will appear as on the right hand side of the screen.
- Color: The color the layer will render as on the screen.
- Line type: Whether the operation will perform along a solid, dotted, or dashed line.
- Cutting mode: Always set to standard.
- Tool selection: Drop down menu will allow the selection of the tool to be used during the operation, if multiple are allowed.
- Tool insert selection: Select the tool insert (blade or bit) to be used during the operation.
- Initialization: Where the tool will register height from. Alway set to base.
- Clearing distance: How high above the top of the material the tool will retract to travel. Does not need to be adjusted from default.
- Material thickness: Current thickness of the material. Cannot be altered through this window, needs to be set in the material selection window.
- Base depth: How deep relative to the table the material will cut. Should never be more than +/-.005. Adjust in small increments (+/-.002) if blade is not cutting all the way through the stock.
- Multi. pass max. depth: The most stepdown the router will perform on a single layer. Should not exceed .0500in.
- Multi. pass last depth: The depth of the final routing layer. If using bridges, should be at least .0200in, as bridges are formed from this layer.
- Machining depth: The specified depth for engraving operations.
- Score depth: The specified depth of a score, either in inches or percentage of material thickness.
- Acceleration, tool lowered: The maximum acceleration the tool will travel while cutting the material, from 1-4.
- Speed, tool lowered: The maximum speed the tool will travel while cutting the material. Slow down for a cleaner cut in most materials.
- Knife compensation: Offsets the cut to compensate for the thickness of the blade (generally unnecessary).
- Speed, lowering tool: The speed a tool will lower between steps. Must be >5in/s for routing operations.
- Router speed: Speed the bit will spin during routing operations. Should not be adjusted.
Orange parameter boxes signify that the setting has been changed from the default. On the right side of the window is a representation of the current stock thickness next to a representation of the specified cutting depth. The red line on the routing operation represents the thickness of the Sealgrip underlay. The alternating light and dark gray rectangles represent the number and depth of each multi pass step to be performed. The green line above the material is the clearing distance. Advanced settings
The second tab lists advanced cut settings. These should never be adjusted, with the exception of Overcut, if less or more overcut is desired during a cutting operation. Overcut defines the offset from the original start and stop point of each vector. Some knives, particularly wider geometry knives and the DRT rotary blade create a significant amount of overcut. When cutting out thin features, this overcut can unintentionally cut completely through those features. Some overcut is inevitable when using thicker materials, such as foamcore, and if prisitine pristine cuts are required, the file should be set up to use the bottom side of the foamcore as the clean side, as that side experiences much less overcut than the top side. <insert examples of overcut> Performing a Tool Change
Red tool labels and red 'Start job' button in Cut Center indicated that the tool specified by an operation is not currently installed in the machine and will required a tool change. Widget Connector |
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- Remove the EOT from the machine if it is currently installed.
- Carefully rest on the table such that it won't fall off.
- Loosen the set screw to release the blade.
- Remove the blade and place back into its labeled container.
- Insert the new blade into the EOT with the
longer point of the blade in the center of the EOT and cutting edge facing the outside of the tool . - Ensure that the blade is in place by checking that the chamfered side of the cutting edge on the blade is aligned direct with the surface of EOT and tighten the set screw.
- Install the EOT into the tool holder, aligning the red dots of the EOT to that of the tool holder.
- Hold down the belt lock button and turn the EOT clockwise until the first notch on positioning bracket is engaged the registration post of the tool holder.
- Once the EOT is position, connect its cord into the
black power socket of the ICC camera module. - Initialize the EOT.
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