Some impressive machining!

I had programmed CNC machines many years ago when you would mimic the movements that a operator would use to make the same cuts. I cannot imagin that someone programmed these movements of the head and piece in 3 dimensions. How is it programmed??

Pretty cool must be a $10k paper weight.
 
With expensive software...5 axis capable. Right now, I use Mastercam for my machining needs but I only utilize 3-4 axis at any one time.

If only that helmet costed 10k....I am sure the number is substantially higher.
Program time within that piece would be enormous...Possibly a week give or take a day.
40hrs x $100hr= 4k just for programming. It is always the first part that costs big bux...
 
That is nuts!

I am no machinist by any stretch of the imagination so please forgive me if the question I ask is beyond ignorant. Is there any kind of technology that scans 3-dimensional objects and then builds the program based off of the scan? Or is that just science fiction voodoo?

However they did that it is very impressive. The details are crazy. All they way down to the pattern on the padding on the inside of the helmet.

SDS
 
My brothers Company does Reverse Engineering for Jet Aircraft engine Re-builders. Programming for the CNC is created by laser Optical imaging in 3D of the original part, then the DXF file is loaded into the CNC.
He can create a DXF file for anything you care to replicate.
 
TheArizonaKidd.com said:
My brothers Company does Reverse Engineering for Jet Aircraft engine Re-builders. Programming for the CNC is created by laser Optical imaging in 3D of the original part, then the DXF file is loaded into the CNC.
He can create a DXF file for anything you care to replicate.
Click to expand...


I have never heard of a laser optical machine actually programming a CNC before. Not that it doesn't exist, but lasers that are used for reverse engineering create an object called a point cloud. This point cloud then needs to be stitched into surface entities and finally turned into a solid to which it then can be programmed. There is alot of manual input when it comes to programming CAD/CAM now, but that does not mean they are not working on getting rid of my job in the future..Just don't see it happening anytime soon.
 
That is freakin outrageous!!!!!!!!!!!!!!:cool:
German technology I believe, anyway that is what the language looks like.
It is just amazing what one of those machines can do! :thumbup:
 
...That... made me feel all tingly...

The machining is pretty slick - I particularly like the effect they achieved with different surface finishes. But the underlying geometry is what blows me away. The design and surfacing in the geometry is top notch.

I would expect something like that was designed in Alias or Catia and programmed in something like Delcam. I think MasterCAM could probably do that. I don't think Gibs 5 axis would be quite up to that, though perhaps with a really good programmer. I use Pro/E and the 5 axis isn't that great. The only 5 axis work I've done was some thermoform molds on a big Thermwood and I gave up trying to do full 5 and had to do 3+2. It ain't easy to do well, and crashes are a lot harder to predict than a three axis.

DXF files are generally 2D type stuff. Laser scanned point clouds of a physical model can be stitched together, but quality geometry is very labor intensive. But the actual programming of a machine involves someone sitting down and developing a machining strategy involving cutters and tooling and fixtures etc that they apply in a way that the geometry is supported while cutting, stock allowance is left after roughing to prevent gouging and on and on etc. The experience and knowledge of the programmer and the automated caned routines in the CAM system combine to generate tool paths that are translated into machine specific G code. A lot of the most skilled parts of this is the reference geometry the programmer creates to drive the angle of engagement of the cutter on the underlying geometry to optimize surface finish and to be able to reach all the little nooks etc.

Some basic 3 axis stuff can be automated, and that includes things like simple mold cavities ect. But a part like that helmet took a very skilled CNC machinist/programmer a lot of time, I think 40 hours of $100/hr programming was a good guess. I don't think that will ever be automated (at least any time soon). It requires a human in the same way that an automated program would never be able to write this post I just wrote. Too many variables.
 
CliveJericho said:
here's a translation of the title:


I think it's a motorcycle helmet
Click to expand...

Motocross helmet. Regular motorcycle helms dont have the visor normally.


That is one amazing machine. I think I could get it to cut a square or make a cylinder. :p
 
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Nathan, thanks for the input. I just wish I knew what all of that means! I feel like I'm watching a Charlie Brown where the grown ups are talking when I listen to machinists talking. I just hear "wom wom wommm womm wom, womm wom...........".

I hope to take a basic machining class but it's going to have to wait awhile.

SDS
 
Was that a programming error ? The block moved at the cut then when the tool hit the block again it broke. Programming or loose mounting ?
 
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