Custom Shaped Mazes
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- Vectric Wizard
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Custom Shaped Mazes
This is admittedly a plug for my recently finished software project but this is compatible and synergistic with Vectric software so I hope this is O.K. here...(I guess the admin will remove if not ). Unfortunately I am not proficient with the tools to make this a Vectric Gadget and it may be too complex for that, anyway. But with the .dxf vector import the output of this app can be used in VcarvePro or Aspire just as well.
I had been working on a PC app that calculates single or double side mazes (cylindrical as well) of custom shapes for a while. I finally wrapped this up and did a rather complex test piece as proof of concept. The purpose of this software is simply to create and machine mazes as toys and gadgets, maybe also for therapeutic value or as decorative pattern/textures for wall art, signs and the like. These can be open ball channel or with captive undercut ball channels. If you want to know more, please see here.
Starting point for my demo project was a random bitmap image of a horse. This could have been color or grayscale but B/W works best:
This was converted to a maze tile blocking pattern using the app. The green tile defines the starting point for the maze generator:
More pictures to follow.
I had been working on a PC app that calculates single or double side mazes (cylindrical as well) of custom shapes for a while. I finally wrapped this up and did a rather complex test piece as proof of concept. The purpose of this software is simply to create and machine mazes as toys and gadgets, maybe also for therapeutic value or as decorative pattern/textures for wall art, signs and the like. These can be open ball channel or with captive undercut ball channels. If you want to know more, please see here.
Starting point for my demo project was a random bitmap image of a horse. This could have been color or grayscale but B/W works best:
This was converted to a maze tile blocking pattern using the app. The green tile defines the starting point for the maze generator:
More pictures to follow.
Last edited by Tailmaker on Wed Jun 14, 2017 3:40 am, edited 1 time in total.
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- Vectric Wizard
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Re: Custom Shaped Mazes
As a next step, a random maze is generated, controlled by various parameters like branch length and "wrinklyness". The green circles are the pre-defined starting point and the random end point. The thin green trace shows the single path from the start to finish. This happens to be a single sided maze, but a double side maze (with transition holes) can be made as well, much bigger effort, though.
This can be exported as .dxf with layers for pre-slotting and perimeter cutout with end mill, undercut machining with a ball end plunge bit and chamfering with a v-bit. After import into VcarvePro it may look like this:
The cut simulation in VcarvePro looks like below. However, the actual undercut of the ball channel can not be simulated (as far as I know):
The blank could be held down with clamps and leaving an onion skin but for me it is easier to make a custom vacuum pod and cut through at the perimeter:
More pics in next post.
This can be exported as .dxf with layers for pre-slotting and perimeter cutout with end mill, undercut machining with a ball end plunge bit and chamfering with a v-bit. After import into VcarvePro it may look like this:
The cut simulation in VcarvePro looks like below. However, the actual undercut of the ball channel can not be simulated (as far as I know):
The blank could be held down with clamps and leaving an onion skin but for me it is easier to make a custom vacuum pod and cut through at the perimeter:
More pics in next post.
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- Vectric Wizard
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- Joined: Sun Jun 16, 2013 4:40 am
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Re: Custom Shaped Mazes
Starting the slots with a downcut end mill in phenolic clad baltic birch:
Routing the undercuts with a 1/4" ball end plunge bit. The path is routed 4 times in/out and up/down to widen the channel sufficiently for a 1/4" steel ball (e.g. 0.2" or 0.5mm play):
Usually I make such mazes for 1/2" balls but this one was made for 1/4" to get the most complicated one with the available machining range of my CNC. However, ball end plunge bits in 1/4" are hard to come by (except from Harvey Tools for serious money) so I used a simple 1/4" ball end burr from McMaster. It made more dust than chips but with some air jet support it worked well:
I am quite happy with the result. Well, at least as a show piece. I can not find the way myself from start to finish unless I cheat and look at the screen picture.
Routing the undercuts with a 1/4" ball end plunge bit. The path is routed 4 times in/out and up/down to widen the channel sufficiently for a 1/4" steel ball (e.g. 0.2" or 0.5mm play):
Usually I make such mazes for 1/2" balls but this one was made for 1/4" to get the most complicated one with the available machining range of my CNC. However, ball end plunge bits in 1/4" are hard to come by (except from Harvey Tools for serious money) so I used a simple 1/4" ball end burr from McMaster. It made more dust than chips but with some air jet support it worked well:
I am quite happy with the result. Well, at least as a show piece. I can not find the way myself from start to finish unless I cheat and look at the screen picture.
- kp91
- Vectric Apprentice
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Re: Custom Shaped Mazes
Great looking project. I have a daughter that would love that!
Doug
1 John 1:9
Fredericksburg, VA
1 John 1:9
Fredericksburg, VA
- mtylerfl
- Vectric Archimage
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Re: Custom Shaped Mazes
That is cool! Besides being a functional maze, I like it simply for its artistic appearance too. Great work!
Michael Tyler
facebook.com/carvebuddy
-CarveWright CNC
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facebook.com/carvebuddy
-CarveWright CNC
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- Vectric Wizard
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Re: Custom Shaped Mazes
Very interesting work. Nice result.
We have manufactured much bigger (but simpler and rectangular) labyrinths for a customer.
We machined it a different way:
1) cut partially a first layer with a large end bit
2) glue a 2nd layer on top
3) cut entirely the 2nd layer with a smaller end bit
Allows use of standard bits, a better chip removal and higher steeps than a ball bit.
Do you plan to release your software?
We have manufactured much bigger (but simpler and rectangular) labyrinths for a customer.
We machined it a different way:
1) cut partially a first layer with a large end bit
2) glue a 2nd layer on top
3) cut entirely the 2nd layer with a smaller end bit
Allows use of standard bits, a better chip removal and higher steeps than a ball bit.
Do you plan to release your software?
Best regards
Didier
W7 - Aspire 8.517
Didier
W7 - Aspire 8.517
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- Vectric Wizard
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Re: Custom Shaped Mazes
It is released, see here: http://www.tailmaker.net/mazes-1.htmlLittleGreyMan wrote:Very interesting work. Nice result.
We have manufactured much bigger (but simpler and rectangular) labyrinths for a customer.
We machined it a different way:
1) cut partially a first layer with a large end bit
2) glue a 2nd layer on top
3) cut entirely the 2nd layer with a smaller end bit
Allows use of standard bits, a better chip removal and higher steeps than a ball bit.
Do you plan to release your software?
The main purpose of this software is the quick conversion of an image outline and random maze pattern generation within that boundary (which is by default rectangular if no image is imported). It takes only minutes to get the vectors. If the result is to be simulated or integrated with other shapes or tool paths or projected onto a 3d-object, this will need VcarvePro or Aspire.
Actually, I started out making mazes with 2 glued layers but found it more elegant and easier to cut them out of a solid board. Just less problems with glue residue or wood fuzz to obstruct the ball channel. 2-flute ball end plunge bits for 3/8", 1/2" and 5/8" are not a problem and easy to get e.g. from Magnate. A 4-flute 1/4" bit is only available from Harvey Tools for a whopping $45, but the much cheaper ball end burr worked actually quite well. Chip removal is not really an issue, because the end mill slot is machined first and goes through almost to the bottom of the ball channel. That means all that remains to be removed by the ball end bit is the actual undercut and the rounded bottom of the channel that can not be reached by the end mill.
The other reason for this method is the option of machining a 2-sided maze where the ball transitions to the other side and the maze is to be flipped over and an option of machining a cylindrical maze on the rotary axis.
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- Vectric Wizard
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Re: Custom Shaped Mazes
Thanks for the link, i'll give it a try.
No doubt your method gives better results for small decorative mazes, especially for balls and plain wood.
In the case of my customer, he needed a 1310x685 mm (more than 51x24") black MDF maze and the token was not a sphere. Each MDF layer was 19mm (about 3/4"). With this size, you're looking for speed and good chip removal.
I think he may be interested by double sided or cylindrical labyrinths.
Sorry, I cannot post any picture.
No doubt your method gives better results for small decorative mazes, especially for balls and plain wood.
In the case of my customer, he needed a 1310x685 mm (more than 51x24") black MDF maze and the token was not a sphere. Each MDF layer was 19mm (about 3/4"). With this size, you're looking for speed and good chip removal.
I think he may be interested by double sided or cylindrical labyrinths.
Sorry, I cannot post any picture.
Best regards
Didier
W7 - Aspire 8.517
Didier
W7 - Aspire 8.517
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- Vectric Wizard
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- Joined: Sun Jun 16, 2013 4:40 am
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Re: Custom Shaped Mazes
I did cough up the money for the 1/4" Harvey Tool bit and gave it a try on a piece of solid brass. This job was a challenge for my wood router. When the ball end bit hit the corners and ends of the pre-slotted channels, it chattered quite a bit. Eventually it worked but I guess this is more the territory of a real CNC mill.
This is a 2-sided rectangular maze and I repeated the random maze generator (probably 50-100 times) until the finish cell of the maze ended up in the same x/y position as the start cell of the maze but on the opposite side and drilled through. That means this maze constitutes an infinite loop. Now I only need to close the transition holes with brass wire staples. The staple holes are already drilled.
This is a 2-sided rectangular maze and I repeated the random maze generator (probably 50-100 times) until the finish cell of the maze ended up in the same x/y position as the start cell of the maze but on the opposite side and drilled through. That means this maze constitutes an infinite loop. Now I only need to close the transition holes with brass wire staples. The staple holes are already drilled.
- scottp55
- Vectric Wizard
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Re: Custom Shaped Mazes
Brass one is Purty Tailmaker!!
I've learned my lesson well. You can't please everyone,so you have to please yourself
R.N.
R.N.
- Leo
- Vectric Wizard
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Re: Custom Shaped Mazes
I have to admit, I like the brass one.
I also know about Harvey bits - big money - but they have some unique stuff.
I also know about Harvey bits - big money - but they have some unique stuff.
Imagine the Possibilities of a Creative mind, combined with the functionality of CNC