Contact Info:

Questions or Comments?
erik@foamcasualty.com
July 2011: FW-190A Plans are now up for grabs! Get them while they are hot! If you need parts for any kit please send me an email!
July 2011: Kits will be available soon, parts are available now! If you are interested, please email me at erik@foamcasualty.com

A resource for the Scratch Builder

Thank you for your interest in our 6 axis CNC system.
CNC Product Brochure
Specifications:

  • Fully capable of 6 axis of computer controlled movement
  • Capable of switching to 3 axis mode to use standard x,y,z g-code.
  • Designed specifically to mill and hot wire cut foam
    (heavier materials are not recommended to be milled and can not be hot wire cut).
  • Over 75 5mm ball bearings ensure smooth hotwire motion.
  • Delron wheels with installed bearings provide smooth action and excellent wear resistance against engineered aluminum rails.
  • Wheels utilize a cam design to allow for adjustment to ensure a precise fit.
  • Sheet metal parts are fabricated on a CNC hydraulic break out of 1/8 inch 5052 Aluminum
  • Durable powder coat resists corrosion and wear to sheet metal parts and is available in red, white, and blue.
  • Machined parts are fabricated from 6061 billet aluminum and are anodized for longevity.
  • Designed to allow complete travel over a 24" x 48" x 12" cut area
  • The hot wire bow is 7" deep and utilizes a dedicated fused 24VAC supply, drawing less then 1 amp.
  • Wire tension for the hot wire bow is adjustable up to 10 lbs.
  • Unique Z drive belt drive system minimizes cost and limits backlash
  • Micro switches provide for homing capability on all axis and provide for an e-stop cutout along Y&V, X, and +Z&W axis.
  • Machined aluminum switch "dogs" are adjustable to the limit switches and provide for a hard stop.
  • Spindle drive utilizes a brushless DC motor rated at 2700KV and is calculated to allow over 20,000 rpm head speed
  • Machine stand is fabricated out of 3/32 aluminum, powder coated and includes pressed in hardware with over 2 inches of adjustment built into the legs.
  • Computer control solution is provided as plug and play, with LinuxCNC ready to go.
  • Machine and control solution include a no hassle one year manufacturer warranty.

Machine and Control Solution manufactured in Halethorpe, Maryland at 4764 Hollins Ferry Road 21227 by Logan Machinists Inc, distributed by Foam Casualty LLC P.O. Box 167618 Oregon, Ohio 43616

Here are some of earlier video we have done, all of the same machine in various modes of operation. The machine is shown running a 4 axis wire program, followed by a 3 axis mill program, followed by a 4 axis wire operation in the same program:
The machine is shown running a 3 axis wire program (F6F Hellcat Canopy Plug):
The machine is shown running a 3 axis wire program, followed by a basic hotwire operation to release the part from the bulk stock foam (F6F Hellcat Cowling Plug):
All software utilized is available for free on the internet.
The machine controller is linuxCNC, and ships pre configured ready to run. The cam software is Google Sketchup, the pro version is not required, and we will include the same plugins we are using to generate the code for the models seen on this site. (A Link for the plugins will be posted here shortly)

Travel and cut area is designed to be 24 inches by 48 inches, by 12 inches in the Z.
Can operate in 3 axis xyz mill mode (+1 axis for the a axis) or 4 axis hotwire mode, and can change on the fly while running your nccode (gcode) routine.

WARNING
CNC machines, as such the one(s) advertised on Foam Casualty LLC can be very DANGEROUS to the operator, the surrounding property, or bystanders! When around the machine, whether in operation or not, ALWAYS place safety first, ALWAYS exercise sound judgment, and ALWAYS consult the manual before use. ALWAYS WEAR SAFETY GLASSES when assembling this product and while it is in use! Due to the nature of the rotating mill head and the small diameter wire, that is designed to be heated above 200 degrees while under tension, the possibility for serious injury and extensive property damage always exists. This product by design REQUIRES a tensioned wire that when in use will be EXTREMELY HOT and WILL CAUSE BURNS to bare skin or FLAMABLE MATERIALS in contact with the wire. The wire should be considered to always be HOT and EXTEREME CAUTION should be used when working around the wire. The wire is considered a perishable part and should be replaced regularly to avoid an unexpected sudden failure. Regular maintenance up to and including changing the wire WILL NOT guarantee the wire will not suddenly and unexpectedly break or slip from the tensioner device. ALWAYS WEAR SAFETY GLASSES! The wire requires electricity to be heated and the possibility of electrical shock exists, it is STRONGLY recommended that a Ground Fault Interrupter outlet circuit is used to power this machine and any other advertised on this website. NEVER leave the machine unattended while in operation. Use of this product may result in very serious injury or extensive damage to property.

Pricing:
$3500USD plus shipping
If you are interested, please send me an email:
Erik@foamcasualty.com