Shuttle Engraving for Looms by CNC Routers

Precision machining of a shuttle used in textile looms has undergone engraving iterations in the process. Man invented the shuttle to help the weaving process. A weaving shuttle is shaped like a boat carrying a bobbin of thread across the warp threads to form the weave. Repeated movement of the shuttle from left to right and back creates the weave ultimately forming the pattern of cloth.

Shuttle Carving

When it was first invented carpentry and carving skills was required. The basics of shuttle design began from a crude boat design (by the way this design is still used) that held the bobbin of thread. Employing a drill brace and a couple of bits to bore holes into the shuttle was enough to ferry the bobbin back and forth. From hand tools has the shuttle carving and engraving metamorphosed today to CNC router applications. Shaping the shuttle from the outside to fine placements of holes to create shuttle eyelets is just a matter of minutes for CNC routers. To prevent wear and tear in the eyelets as the thread passes back and forth small brad is precision-engineered. The complexity of engraving in the olden times with basic carpentry tools is indeed admirable compared to modern carving and engraving precision employed by CNC routers. This double technology process optimizes working times and productivity.

A fine example of using CNC routers for engraving shuttles is captured in this video 

The CNC router is manufactured by OMNITECH from China. They are one of the leading manufacturers of CNC routers. A basic Omni CNC router is all that is needed for precision carving and engraving shuttles. The built-in controller is input with predetermined tool path files that can be used repeatedly. The art of weaving extraordinary designs using thread of different materials like plastics, nylon, wool, synthetic silks among others has created a spin off industry in handwoven textiles. Design houses have sprung up all over the world. These spin offs have redefined shuttle manufacturing. Emailing tool paths to woodworking shops with CNC routers and receiving manufactured shuttles, via mail is as easy as posting letters and receiving a reply. The speed of CNC operation makes it possible to order as many shuttles as possible.


CNC Routers Enhance Architecture Facade Design

The versatility of CNC routers is incredibly vast in scope and application. There are many areas particularly industrial application that offers creative expression. The example of creating stunning facades in building construction is a prime example.

CNC routers are commonly used in profiling aluminum sections for fabrication service industry. Substrates include aluminum composites, high pressure laminates, Acrylic, MDF Corian, HDPE among others that is regularly profiled and cut using CNC routers. Miller Design in Australia is one of the leading votaries of using OMNITECH's cutting edge CNC routers.

They provide complete integration of design to installation of curtain-walling systems, shopfront facades and roof glazing. They are a name to reckon with and won many awards for the high quality of their installations that involve intricate aluminum joinery.

OMNITECH CNC ATC (automatic tool changer) Router is essential equipment in Miller Design's arsenal. OMNI also offer production, technical expertise and consultation to Miller and this partnership is more of actual creative minds meeting on a common platform to produce architectural beauty.

Miller Design specializes in curtain-walling design where two or more floors of a front facing façade appear to be continuous and seamless. Reflective glass mounted on structurally glazed mulions which are concealed help this stunning architecture. Engineering design and accurate cutting of aluminum profiles is the expertise behind this kind of architecture design. Retrofitting existing buildings is also possible with curtain-walling.

Dejan from Serbia is another of those enlightened visionaries who uses OMNITECH's ATC type CNC router for aluminum composite machining. He uses thick aluminum sheets of 4 mm thickness while his panels range in thickness from 2 to 10 mm. Some of his windows, glass facades and ventilated facades are a joy to behold for structural as well as aesthetic appearance.


How CNC Router Could Benefit Cricket Bat Processing Business?

Cricket is a sport played mostly in countries that have a colonial history. As the colonies broke up and the sun began to set on the British Empire the game of cricket continued to thrive in these areas. There was however a jewel in the crown of the breaking British Empire. India at the midpoint of 1950s had a population around 350 million people. In a span of five decades, the population soon touched a billion and along with China forms the two largest countries in the world population wise. The winner is cricket. India rules the cricket world in numbers. The demand for cricket equipment is witnessing boom time.

Bat Manufacturing

Cricket bats are at the center of the equipment business. The bat manufacturing centers in England pioneered the use of English willow. As demand, outstripped supply Kashmir willow became the wood of choice and bat manufacturing concentrated in Kashmir. Being a populous country, every aspect of the bat was handmade and no two bats could be termed the same. Professional cricketers would spend days with a reputed bat-maker to personalize weight and size (within the stipulated laws of cricket) of the bat. A top rated cricketer would have a dozen bats in his kitbag.

CNC Router Process for Bat Profiling

England started the manufacture of bats using machines and soon it became apparent that CNC Router machine was the perfect tool for creating bats. Two-piece bats dominate the manufacture. The body of the bat is married to a cane handle via a splice. CNC routers have simplified the operation by using a single piece of willow (130 mm x 130 mm x 850 mm) that clamped onto a 12 spindle OMNI CNC Turner/Lathe Router. A milling tool of 1/2 x 60 and 1/2 x 120 is mounted and the block of willow fixed to the rotary device after finding the center point of the willow block. The CNC Router has the profile of the bat input into the computer, which guides the milling tool and process the willow block into the desired shape in one single piece.

Bat Dynamics

Bats usually have a raised ridge at the back of the bat and a straight face on the front. The front face meets the incoming ball and imparts force that is termed as a stroke. The force of the stroke is either brute power or timed stroke without using brute force. Twenty-twenty Cricket has changed bat dynamics resulting in strokes played of the back of the bat. Profile of the bat includes scooped back that is almost similar to the front without sacrificing the sweet spot on the face. Sweet spot’s indication is the noise of a solid thump when ball meets bat. The scooped back enables a batter to hit off the rear of the bat or reverse the bat in his hands in a lightning fast movement (called as reverse sweep).

Allen Tells You How to Process The Cricket Bat by CNC Router China-

Bat manufacturing business using CNC Routers is a game changer. Small CNC Router with two spindles can personalize bat for a person taking into account height, weight and batting style of the sportsperson. Small profiling adjustments to the blade of the bat smooth edges resulting in faster carry of the ball. The game of cricket is witnessing rapid changes in attacking style; more strokes are played when compared to before and cricketers are making serious money both on and off the field. It is not only international stars but also the lower ranked cricketer making a comfortable living.


EPS Pattern making by CNC Router

The similarity between lost wax casting and lost foam casting (LFC) is almost the same. The main difference is the use of EPS (expanded polystyrene) instead of wax. EPS is the disposable element. The only difference is the pattern remains in the sand mold. The hot metal will decompose the mold. The origin of this process dates back to 1958. H. F. Shroyer the originator called it the full mold process. In the early days, the patterns were machined on expanded polystyrene blocks and molded in sand that had furan resin as a bonding agent. Luckily, the patent expired in 1980 and it became available in the public domain.

The process of casting using EPS patterns explained in the following steps

  • Patterns machined with pre-expanded EPS 
  • Pattern is coated with refractory
  • Pattern is placed in a flask
  • Sand is filled into the flask
  • Liquid metal is poured into the flask
  • EPS melts or vaporizes
  • Pattern is shaken loose for the casting to emerge

The alternative for EPS is expanded polymethyl methacrylate (EPMMA). Sometimes the two are mixed together to obtain a blend. Polycarbonate is another material that used in the LFC process.

Forming the Pattern
These are the various steps in the pattern making
  • Design the part
  • Tooling design for the EPS foam
  • Tooling design decides initial dimensions
  • Different sections of foam design
  • Ultimate foam pattern quality and fusion of foam to refractory coating

Tool design of foam patterns take into account holes in the foam and pullbacks for undercuts. The design also incorporates collapsible cores for making large internal hollow sections in the foam. The complexity of the design involves making several sections of foam that are joined together in a final assembly to arrive at the final pattern To carve each foam section a tool and suitable fixture is designed so that correct alignment of sections are glued.

Tool designs generally are a long process. With the advent of the CNC router tool design and foam section carving is automated. Prototyping involved gluing hand carved foam sections and the resulting cast was inferior in quality that needed careful machining. Today 3d printers have made complex designing of parts user friendly. The same design is transferred via CAD / Cam software to an EPS shaping CNC router machine. The router creates the foam patterns. When all the foam sections are assembled together the pattern is filled with unbonded sand. Hot metal is poured and allowed to cool. The foam vaporizes. The sand mold is shaken loose and reused for the next casting process. The resulting cast is almost perfect that requires very little machining.

Cylinder blocks for automobiles use this process widely. Formula one engine constructors like McLaren and Ferrari have their own pattern making workshops that are state-of-the-art.

OMNI CNC EPS shaping router machine is widely used in die and mold industries. The machine‘s versatility can be gauged because it is used on expanded polystyrene, wood, and other non-metallic molds.

They have found special use in
  • automotive foam mold
  • wooden ship modeling
  • wooden aviation modeling
  • model trains 

Multifaceted Use of Wooden Crown Moldings

Wooden crown moldings have been used as decorative motifs from time immemorial. The early wood workers used various profiles that gave different shadow effects. Wood moldings were made from solid wood until gypsum or plaster of paris made its entrance and provided an alternative. With engineered woods and plastics, profiling of trims has reached another level for interior decorative trim.

Moldings have beveled edgings on two faces that are at right angles to each other. This allows fixing them to the wall and the ceilings. There are plain moldings, sprung moldings, cyma moldings, and ogee moldings among others. Moldings were introduced to add the dimension of shadow play on a wall. Adding a small overhang to the surface of the wall created different patterns of light and shadow to give an architectural effect. By changing the shape of the overhang, graded shadow effects became possible.

Decorative moldings from stone, plaster and wood are normal. Cyclopedia printed in 1728 has a chapter devoted for various types of moldings under the heading Table of Architecture. Woodworking tools were commissioned that were termed as specialized planes. At one time, a woodworking shop had to have as many molding planes as were the designs. You can imagine the shop with hundreds of planes. In the 19th century, the English multi-plane became the wood workers choice for molding work. This tool allowed interchangeable blades. When the crown moldings became large (in the order of 6inches or more) then pushing the plane required great force Sometimes two people needed to push and pull a plane for oversized moldings.

Today this is not a problem. Any woodworking CNC router will do the job in a matter of minutes. Profiles of moldings are stored as readymade drawings. The design can also be tweaked and in no time, a new molding design can be carved. Interchangeable router bits can cut variety of profiles.
Other than using between ceiling and wall, crown moldings are used in imaginative ways to enhance modern architecture with an ornate look. Using below the countertop of a kitchen island is one of the best ways of enhancing kitchen architecture. Adding molding to a plain door will instantly transform the door into an architectural delight and make it the focal point.Moldings are increasingly used to frame mirrors that will make it look more like an art piece.