3-Axis Modular CNC Milling Machine

The 3-axis modular CNC machine for PCB fabrication and milling of soft metals is targeted to improve the electronics manufacturing industry of Pakistan by enhancing local production of PCBs and small mechanical parts.

Project Title

3-Axis Modular CNC Milling Machine

Project Area of Specialization

Mechatronics Engineering

Project Summary

The 3-axis modular CNC machine for PCB fabrication and milling of soft metals is targeted to improve the electronics manufacturing industry of Pakistan by enhancing local production of PCBs and small mechanical parts.

Project Objectives

The scope of the project includes the following deliverables and features: accuracy of 1 micrometer, the work area of 200 x 200 x 100 cubic millimeters or 0.004 cubic meters, auto-probing, homing sequence, wireless control using ESP-32, and a headless operation SD card.

The machine is divided into modules: gantry, z-slide, bed, control box, tool turret, driving mechanism, and calibration and software.

The machine has a precision of 1 micrometer

Project Implementation Method

We conducted a literature review to observe machines similar to ours. The literature review guided our implementation technique, which is why we will be stating what we observed first and then reveal our implementation method. 

• NEMA 23 and NEMA 17 stepper motors were the most used stepper motors for controlling the movement of the X, Y, and Z-axis movements.
• All projects used three unidirectional stepper motors.
• Most of the structures were made from wood because of its low price, strength, and rigidity.
• Only one project used a composite structure made from 6061-T6 aluminum and A36 structural steel.
• Either ball screw or lead screw mechanism was used for translating the stepper motor’s rotational motion to linear motion.
• ATmega328 microcontroller was used to control the functions of the embedded systems of the CNC machines and G-code was used to instruct the CNC machine where, how, and when to move.
• Limit switches were placed in most of the machines to protect the motors from damage.
• 15 micrometers was the maximum accuracy achieved.
• The design and development of the hardware and electronics of the CNC machines were either done on open source softwares or on the student version of softwares.

Our implementation method is in the Technical Details of Final Deliverable section.

To get access to the Detailed literature review click on the link.

Benefits of the Project

.The advantages of CNC machining include high accuracy, faster production, greater manufacturing and tool flexibility, negligible error, and better operator safety. The job of a skilled worker is not occupied by the machine. Instead, it is transformed because skilled CAD designers and CNC machine operators are required by the industry. In 3-axis machining, machining operations can simultaneously be performed on the workpiece along the three planes of the cartesian coordinate system: X, Y, and Z planes. The manufacturing industry uses 3-axis, 4-axis, 5-axis, and 6-axis milling machines. The cost, complexity, and flexibility increase significantly as the axis of the milling machine is increased. 3-axis milling machines are comparatively the cheapest and extensively utilized milling machines in the manufacturing industry because of their relatively cheap cost, simplicity, and capability to remove material in these 3 axes represented by back to front, side to side, and up and down.

Multiple companies across numerous industries are shifting their product design approach from conventional to modular. If not entirely shifting, they are introducing modularity into their products. In modular design, a product is divided into partially independently working modules, units, or elements, which are assembled after they are manufactured. The more independent a module is, the better it is for the overall product, which is the reason dependencies between the modules are kept as low as possible. Modules are designed and manufactured in parallel which reduces cost and increases overall efficiency because resources can be divided, distributed, and allocated across modules, delays do not significantly affect the project timeline. Modular products are better because slight design improvements can be done during the development phase without revamping the entire product. Products can be customized as per user requirements. It is comparatively easier to repair and maintain, install, assemble, and disassemble, and launch a new version of a modular product. Modular products follow the 3 R’s of the environment: reduce, reuse, and recycle.

In the national market, 3-axis modular CNC milling machine is expected to have an unmatched market share because of the unavailability of such a product. In the international market, our product will compete with brands such as Wegstr, Sainsmart Genmitsu, Vevor and RATTMMOTOR

Technical Details of Final Deliverable

• We will be choosing NEMA 17 and NEMA 23 motors as well, due to their cost, specifications, and relevance to our implementation.
• The structure will be made out of comparatively recyclable material. We have narrowed down our choices to acrylic, PVC, HDPE, and LDPE. Aluminum and steel would be used for strengthening the structure at joints and stress concentration points.
• Designing and implementation would be done on open-source software to avoid copyright claims. 
• The electrical section of the machine is divided into components in the items details section below.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Manufacturing

Other Industries

Education

Core Technology

Others

Other Technologies

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com