Topology Mountain - Maui, HI

Files:

Maui Terrain STL - 3D Print

CNC Toolpath

Aspire Toolpath

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The 3D print was used to determine the proper water and drop height before milling.

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Milled Maui Topology

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Workflow

• inspired by the workflow made by Tom Dubick

  Terrain2STL

  Terrain2STL Website

1. Find the desired terrain and define the model area by drawing a red box around the selected terrain
2. Adjust the scale and dimensions of the red box as necessary
3. Adjust the water depth and base height
4. Generate the model and download the STL file as a ZIP

Aspire

New File Setup

1. Open Aspire and create a new file
2. Set Job Type to Single Sided
3. Enter the following dimensions:
   • Width (X): 2.5 inches
   • Height (Y): 3.5 inches
   • Thickness (Z): 1.0 inch
4. Set Z Zero Position to Material Surface (Top)
5. Set XY Datum Position to Bottom Left
6. Choose Model Resolution to Standard
7. Click OK

Importing and Orienting the 3D Model

1. Go to the Modeling tab
2. Click Import a Component or 3D Model and select the STL file
3. Open Transform under Imported 3D Model settings
4. Set Rotation about Z axis to 0 degrees
5. Uncheck Lock XYZ Ratio
6. Set dimensions to:
   • Z = 1
   • X = 2.5
   • Y = 3.5
7. Click Apply and center the model
8. Leave Apply Perspective Along Z unchecked

Positioning and Component Settings

1. Ensure Depth Below matches the Z height of the model
2. While set to Position Relative to the Modeling Plane, click Import
3. Go to the Component tab and open Component Properties
4. Set:
   • Shape Height: 1.0
   • Base Height: 0.25
5. Click Close

Design Setup

1. Switch to the Design tab and select 2D View
2. Click Center under the Alignment Tool
3. Go to Design → Create Vectors
4. Draw a rectangle around the design with dimensions:
   • X = 2.5
   • Y = 3.5

Toolpaths

3D Roughing Toolpath

1. In the 2D view, select the 3D model image
2. Click 3D Roughing Toolpath
3. Set:
   • Material to Hardwood
   • Tool to Large 25 mm End Flute Mill (1/8 End Mill)
   • Machine Limit Boundaries to Selected Vectors
   • Machining Allowance to 0.024
   • Strategy to 3D Raster
4. Name the toolpath and click Calculate

3D Finishing Toolpath

1. Select 3D Finishing Toolpath
2. Set:
   • Material to Hardwood
   • Tool to 1/8 Ball Nose
   • Machine Limit Boundaries to Selected Vectors
   • Strategy to Raster with a 0 degree angle
3. Name the toolpath and click Calculate

2D Profile Toolpath

1. Select the rectangular boundary
2. Choose 2D Roughing Toolpath
3. Set:
   • Start Depth to 0
   • Cut Depth to 0.5
   • Material to Hardwood
   • Tool to 1/8 End Mill
   • Machine Vectors to On
   • Direction to Climb
   • Leave Separate Last Pass unchecked
4. Name the toolpath and click Calculate

Final Steps

1. Preview all toolpaths
2. Save the G-code using Save Toolpath
3. Select Machine as Carvera Desktop CNC Machine

MakeraCam

1. Save the toolpath to the Fab Lab drive
2. Download and import it into MakeraCam on the PC by the CNC machine
3. Upload the G-code
4. Set the offset to (6, 6) to center the cut on the wood
5. Watch the toolpath preview
6. Run the G-code

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Issues Encountered

The only issue I encountered while working on this project was in the setup of MakeraCam prior to milling on the CNC machine. From a previous mill, Auto Set by Offset had been set to Anchor 2 when it should have been set to Anchor 1. This caused the drill to go into the baseplate and off the toolpath. After stopping the machine and editing the settings, I restarted the mill. The second time the CNC machine successfully ran the g-code. Below is a photo of the setting after editing and where the drill went into the baseplate of the CNC machine.

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Reflection

My biggest takeaways from this project were learning how to create toolpaths in Aspire and using MakeraCam with the CNC machines. Due to trying multiple variations of Maui with various water and base heights, I not only became more comfortable with the Aspire and the various toolpaths, but also reinforced my skills on the 3D printers. Due to my issue with the setup in MakeraCam, I am much more familiar with the processes in the software as well as the physical setup in the CNC machine. If I were to redo this project, I would want a larger square piece of wood. As my design was a square and I did not want extra space filled by just water, I was constrained to a smaller area for my mill. I plan on building a base out of small wood pieces and engraving the Island name into the wood.