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Dremel Carver/Duplicator like a Human Powered CNC Router

by Adran on January 4, 2009

Table of Contents

intro: Dremel Carver/Duplicator like a Human Powered CNC Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 1: Design Intent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 2: Rev 1.1 - Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 3: Rev. 1.1 - CAD Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 4: Rev. 1.1 - Wood Pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 5: Rev 1.1 - Metal Pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

step 6: Rev 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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http://www.instructables.com/id/Dremel_CarverDuplicator_like_a_Human_Power_CNC_Ro/
intro: Dremel Carver/Duplicator like a Human Powered CNC Router
For the last few years I have seen all these cool CNC projects from affordable rapid-prototyping machines, to laser cutters, to hacked together CNC routers. One of these
days when I have the funds, I will build one of these CNC machines but till then I thought I would do something more on my budget.

I have a Dremel and have been buying various router bits for it lately. I was thinking that I could buy one of those Dremel Router tables but, that would be kind of limiting.
So then I thought what about building a Dremel Duplicator. It would have three axes and could be utilized much like a CNC Router with the added advantage of copying
an existing object.

This is my exploration into building a Dremel Duplicator.

Updates:
+ Revision 1.1 - 01.04.08 - Wood and Metal Pipe construction
+ Revision 1.2 - 01.06.08 - Axes improvements
+ Revision 1.3 - Coming Soon!

Video

Video

Image Notes
1. Dremel
2. Stylus a.k.a. Phillips screw driver
3. To be mounted on a board later
4. This axis could moved to the top holes for carving details up to 16" tall
5. Rev 1.1
http://www.instructables.com/id/Dremel_CarverDuplicator_like_a_Human_Power_CNC_Ro/
step 1: Design Intent
My original design intent was to create a Dremel duplicator/carver from readily available and inexpensive materials. This machine should be able to duplicate simple
operations such as holes, channels, and outlines. Ideally this machine would also be able to manufacture complicated 3D objects. Future versions may include
synchronized turntables and a mounting plate to hold items in place.

I had this all planned out: draft a simple CAD model to figure out dimensions, print out pieces to use as a template, cut and drill parts, assemble, document, post to
contest and brag about how this machine cost less than $20 to build, was modular and reconfigurable. Seems pretty easy but it was anything but&

The main stumbling block in Rev 1.1 was that I did not have access to a drill press. The holes in this project need to be exactly aligned, which is really hard to do with a
hand drill.

Rev. 1.2 will show a proof of concept.

Rev 1.3 will hopefully show a refined project.

step 2: Rev 1.1 - Materials

You may have asked yourself, does this work?

And the answer is that it's a work in progress.

The biggest problem was that I used a hand drill because I did not have drill press. All of the holes were crooked and none of the axes aligned. So would this work if you
had a drill press? Maybe, but I think you would still need to come up with an ingenious to increase the performance of the sliding axes. This may be achieved by adding
ball bearings or using UHMDPE plastic.

At any rate I am going to include the printouts and construction documents in case you want build/modify this design. If you build one or have any suggestions please
email me and/or attach a picture.

You can fast-forward to Rev 1.2 to see a working prototype if you like.

Rev. 1.1

Materials:
+ (1) Dremel
+ (1) Phillips screw driver to be used as a Stylus
+ 20ft of 1x2 hemlock (mdf or plywood may be better because it will be less affected my expansion and contraction of natural wood)
+ 5' 11 3/8 of .5 Stainless steel pipe (electrical conduit would be fine)
+ (1) 3/4" or smaller pipe clamp ($0.79Hardware Sales)
+ (1) 1.25" pipe clamp ($1.29 Hardware Sales)
+ (1) 2.5-3" pipe clamp ($1.29Hardware Sales)
+ (16) 2.5 " wood screws
+ (34) 1.5" wood screws
+ (7) .5 " wood screws
+ (6) 8-32 x 1 " screws (this is to lock the Dremel and stylus in place.)

Useful Tools:
+Safety glasses and ear plugs: Safetly First, attempt project at your own risk! I will not be held liable for any injury, medical expense or death as a result of
think about, building or using the project once completed.''

+ Hand drill
+ Miter Saw (hand saw could also be used)
+ Drill press
+ Pipe cutter
+ Various drill bits including 1/8 , 1/4 , .5 or slightly larger
+ Tape measure
+ Ruler
+ Router bits for a Dremel

http://www.instructables.com/id/Dremel_CarverDuplicator_like_a_Human_Power_CNC_Ro/
 Image Notes
1. Pipe cutter
2. Phillips screwdriver to be used as a stylus
3. 14mm and 15mm wood drill bits.
4. 3 pipe clamps: + (1) - 2.5-3" + (1) - 1.25" + (1) - 3/4" or smaller
5. Molly Bolts: These were going to be used to hold the Stainless Steel Pipe in place until I change the design to a free standing unit.
6. Wood Screws: You need an assortment of screw .5", 1", 1.5" and 2.5"
7. Tee Nuts and Screws: This will be used to bolt material to base board
8. Dremel 400 Series:
9. Stainless Steel Pipe: I found this at the Japanese Version of the dollar store, [http://www.daiso-sangyo.co.jp/english/ Daiso] Everything is $1.50 including these
910mm (36") x 13mm dia. (.51") pipe + (2) 18" x .5 " dia. + (1) 19.375" x .5" dia. + (1) 16" x .5"dia.
10. Wood: + (2) 1x2 x 4' Hemlock + (2) 1x2 x 6' Hemlock + (1) 3/4 x 2' x 4' mdf or particle board for base

step 3: Rev. 1.1 - CAD Model

I'm not an engineer, so this is a work in progress.

Image Notes
1. When the arm is attached here, it has a carve height of 16"
2. When the arm is attached here, it has a carve height of about 3".
3. This can travel about 16" back and forth. But this could be increase or decrease with pipe length.
4. This Dremel Duplicator can be easily mounted to different tables

step 4: Rev. 1.1 - Wood Pieces

I used 1x2's because its inexpensive and relative uniform. The materials will be updated soon, I'm working out a few bugs.

File Downloads

Router Duplicator Template.pdf ((792x1224) 21 KB)

[NOTE: When saving, if you see .tmp as the file ext, rename it to 'Router Duplicator Template.pdf']

http://www.instructables.com/id/Dremel_CarverDuplicator_like_a_Human_Power_CNC_Ro/
step 5: Rev 1.1 - Metal Pieces
Metal pipes lengths:

step 6: Rev 1.2

Finally some success! As you can tell from the videos, all of the axes are working properly.

Now I just need to work on the accuracy. The x axis (left and right motion) is quite choppy at the moment. Im going make the arm the entire length of the vertical support
so that it can only move up and down. The new x axis will be the pipe that the Dremel is attached to. Another improvement will be the addition of skate board bearings on
the rails which should improve tool fluency. So stay tuned!

Image Notes Image Notes

1. Counter balance: this is just a scrap piece of tile 1. Adding an additional pipe clamp will reduce twisting of stylus
2. draw sliders
3. Electrical tape and c-clamps hold Dremel and stylus stationary
4. X-Axis is screwed into drawer slider
5. Going to increase width so that this arm will only move up and down in Rev 1.3
6. This is going to be the new X axis on Rev. 1.3

http://www.instructables.com/id/Dremel_CarverDuplicator_like_a_Human_Power_CNC_Ro/
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Comments
7 comments Add Comment

wch says: Mar 27, 2009. 7:22 PM REPLY

I carve mask and gargoles and I have tried to used a dremal yool in my duplicator and found it does not have enough power for any real serious work
,instead use a trim router as it has a lot more power and you will see the chops fly and listen to the people about beefing up your design.

GEEKSRUS says: Mar 4, 2009. 12:30 PM REPLY

Poor design due to limited stability of the axis materials you are using. Try a Arm that reverses the work upside down on the other side of your table opposite
to the model you are attempting to copy, (two tables) an upside down cutting table and the Template table. What does it matter if your dremel drops the
material upside down away from your template model? Consider a stiffer Beam; the wooden amusement park roller coaster is popular because it moves.
Wooden Floors are popular because they flex. Reduce the number of moving parts and increase the strength and sliding flow with brass bushings or lead
bushings, or wheels or something. Nice try though to be nice. Also if you use a seesaw type of setup you can increase the size or reduce the size by moving
your dremel tool up or down the beam on the opposite side of the axis. Note: only if the Beam is 50/50 like a standard seesaw would it produce the exact
copy from he template. good luck

RWReade says: Feb 6, 2009. 5:41 AM REPLY

Looks great, can't wait for you to come up with version 1.3

flaco1 says: Jan 19, 2009. 11:08 AM REPLY

You can increase the stability of your X axis if you increase the width of the Dremel holder and add a diagonal brace from front to rear

PKM says: Jan 5, 2009. 10:26 AM REPLY

This looks like it could be a cool project- a bit like a cross between a key-cutting machine and a pantograph. I wonder whether you will have any problems
with fine detail if your "stylus" isn't exactly the same shape as the engraver bit, but I suppose you could always use an engraver bit for a stylus if you were
concerned about that (and had a suitable work piece, of course).

gmjhowe says: Jan 5, 2009. 4:31 AM REPLY

Unfinished? when you do finish it, be sure to add a video!

jeff-o says: Jan 5, 2009. 6:33 AM REPLY

Yes, I'll be looking forward to seeing how well this works when it's done!

http://www.instructables.com/id/Dremel_CarverDuplicator_like_a_Human_Power_CNC_Ro/