CNC Router Aids Woodworker in 3D Design Production

Grant Nicholson, a woodworker and former graphic designer, sought a tool capable of transforming his design concepts into tangible objects. His search led him to a computer numerical control (CNC) router, specifically for its capacity to produce 3D designs and work with natural materials like wood. Nicholson ultimately chose an LC series CNC router from Techno due to its closed-loop servo control and ball screw drives, which offer enhanced accuracy and durability compared to other systems he considered. The Techno machine's Windows-based CNC interface features look-ahead performance, enabling high-speed routing of 3D parts without compromising position, even for intricate small cavity segments. According to Nicholson, the router has been instrumental in elevating his company, Nicholson Design, to a leading position in his region. The machine's ability to create complex 3D designs, which his competitors cannot replicate, is a significant advantage. Based in Owen Sound, ON, Canada, Nicholson Design specializes in various woodworking products, including wood floor inlays and newels for stairposts. Nicholson asserts that the router's annual return on investment is realized through improved work quality and reduced production time. He views the router as a "virtual chisel," constantly discovering new possibilities it offers. After earning a visual arts degree in 1992, Nicholson gained experience with both small and large companies before spending nine years designing museum exhibits, tourism promotions, signs, and publications for a local government agency. The accessibility of affordable CNC machines capable of producing detailed work played a crucial role in his decision to establish his own business. He contrasted this with the labor-intensive creation processes of the past, where sculptors relied on teams of assistants. In contemporary practice, CNC technology allows for the creation of unique, personalized pieces without the need for extensive manual labor. During his business planning phase, Nicholson explored alternative production methods. While 3D printing offered diverse shapes, its limitation to plastics was a drawback. Waterjet and plasma cutting were considered, but their restriction to 2D objects did not align with his vision. CNC routers, however, provided the versatility to produce 3D designs and work with a wide array of materials, including various woods, foam, plastic, and synthetic wood products. Maintenance and reliability were primary concerns during his selection process. He feared that machine downtime could jeopardize his business. After consultations with a Techno salesman and an in-person demonstration, Nicholson gained confidence in the Techno router's reliability. A key differentiating factor was the use of ball screws for axis movement, which, unlike other machines in its price range, offered superior power transmission, low friction, and extended lifespan. This technology allows for the production of wooden parts with a machine resolution of 0.0005 inch. Nicholson invested in several router accessories that have contributed to his success. The vacuum table eliminates the need for individual clamping, saving significant time when cutting multiple parts. For example, when cutting 200 parts, a full sheet of plastic can be placed on the table, parts nested for optimal material yield, and the vacuum secures them during routing. The micro-drop coolant head is essential for cutting nonferrous metals like aluminum and brass. Additionally, the Techno vision registration system precisely aligns the cutter with printed images, automatically correcting for linear or rotational errors to ensure perfect contour routing. Nicholson utilizes the CNC router to create a diverse range of wooden objects. He has produced newel posts and intricate wood inlays using interlocking pieces of various wood types and veneers. One notable creation is a table featuring a maple leaf carved into wood, surrounded by concentric ripples. He transformed a photograph of a leaf into a toned extrusion and designed the ripple's cross-section to create a 3D shape. This artwork was then machined onto a coffee table's rectangular top, protected by a glass surface. His portfolio also includes kitchen cabinets and custom trim for curved windows. Reverse engineering is another capability, facilitated by a touch probe inserted into the machine's collet. This was exemplified when a client requested a reproduction of a hand-carved wood sculpture with engraving on its 3D surface. Nicholson's LC Series machine automatically copied the 3D image by collecting a 3D point cloud, which he then imported into his design software. Using programs like EnRoute, Adobe Illustrator, Photoshop, and Z-Brush, he manipulated the CAD data and cut the part. This task would have been impossible without the Techno machine. Nicholson also produces 3D engraved signs. This process involves painting or applying vinyl to the sign's background, followed by a masking material. V-carving bits then machine text or imagery into the surface, which is subsequently painted. Upon mask removal, clean, painted edges emerge against the colored background, a level of detail that would be challenging and time-consuming to achieve manually. He created a unique 30-inch diameter Medusa sign by machining the head in two-inch thick urethane sign foam slices to accommodate the machine's z-axis travel, then gluing them together. For wood signs, he sometimes uses images as ornaments, employing "tone extrusion" where image tone corresponds to depth. Darker tones result in deeper relief, allowing a photograph of a maple leaf, for instance, to be sculpted in 3D through image editing, 3D extrusion in router software, and then machined into the sign. Nicholson consistently praises the machine's reliability, noting it has required no service and experienced minimal downtime over three years. Techno's support has been exceptional, providing prompt replacements and remote guidance for issues like a pulley failure or recalibration after an earthquake. Nicholson concludes that the Techno router's diverse capabilities enable him to fulfill virtually any customer request. He highlights how software advancements, combined with these devices, offer designers an unprecedented opportunity to produce ideas in full dimension, in-house, and he continues to explore its expanding possibilities regularly. #CNCrouter #Woodworking #3DDesign #CustomWoodwork #TechnoRouter #DigitalFabrication #Craftsmanship #Productivity #HomeDecor #CNCrouter #Woodworking #3DDesign #CustomWoodwork #TechnoRouter #DigitalFabrication #Craftsmanship #Productivity #HomeDecor