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10. Textile Scaffold

Research

Our meeting with CNC machine and CNC Safety Guidelines


photo by Mariam Baghdasaryan

Our meeting with CNC in FabLab Dilijan started with detailed instructions by Rudolf Igityan. Working with CNC machines requires strict attention to safety. These machines are powerful, fast, and can cause serious injuries if used incorrectly. Below are the essential safety rules and best practices.

1. Personal Protective Equipment (PPE)

  • Safety glasses: Always wear eye protection to guard against flying chips and dust.
  • Hearing protection: Use earplugs or earmuffs if the machine is loud.
  • Appropriate clothing: Avoid loose sleeves, scarves, jewelry, or anything that can get caught in the machine.
  • Closed-toe shoes: Preferably sturdy work shoes.

2. Machine Preparation

  • Check tool installation: Ensure the tool is tightened and the collet is properly secured.
  • Verify workpiece mounting: Clamp the stock firmly so it cannot move or vibrate.
  • Clean the area: Remove any tools, keys, or wrenches from the machine before starting.

3. Before Starting the Job

  • Dry run (test run): Perform a test without material or with the spindle off to check toolpaths and possible collisions.
  • Verify G-code: Ensure the program is correct and matches your setup (origin, offsets, units).
  • Set zero points carefully: Wrong zeroing is one of the most common causes of tool breakage.

4. During Operation

  • Never leave the CNC unattended while it is running.
  • Keep hands away from moving parts, the spindle, and the cutting area.
  • Do not reach into the machine while it is running — stop it first.
  • Stay alert for unusual sounds (vibration, chatter, grinding), which may indicate tool failure or incorrect parameters.
  • Avoid using compressed air to blow chips while the tool is spinning.

5. Emergency Procedures

  • Know the location of the emergency stop (E-STOP) and be ready to use it.
  • Stop the machine if:
  • the tool breaks
  • the workpiece moves
  • you see or hear anything abnormal
  • Disconnect power before changing tools, performing maintenance, or cleaning.


photo by Mariam Baghdasaryan

6. After Finishing the Job

  • Wait for the spindle to stop completely before opening the door or reaching inside.
  • Clean chips with a brush or vacuum, not your hands.
  • Remove the tool if it won’t be used again.
  • Log any issues in the maintenance record.

7. Environmental and General Safety

  • Ensure the workspace is well-lit and clean.
  • Keep flammable materials away from the CNC area.
  • Maintain proper ventilation when cutting materials that produce dust or fumes.

First, we made the tryle with Rudolf by cutting small circle.

After that, we proceed with developing our own 3-d models for cuting them on CNC-machine.

Making model in Blender

Detailed Blender Modeling Process for the Two-Part Mold

1. Starting the Base Plate (Positive Mold Foundation)

  • Opened Blender → File → New → General
  • Deleted default cube (X)
  • Added new cube → Shift + A → Mesh → Cube
  • In Object Mode, scaled it precisely:
  • S → typed 200mm / 2 = 100 (since default cube is 2 m) → Enter
  • Applied scale: Ctrl + A → Scale
  • Went to Item tab → Dimensions: set exactly X: 200 mm, Y: 200 mm, Z: 18 mm

2. Importing the Origami Bird Model

  • Downloaded the STL from Thingiverse: https://www.thingiverse.com/thing:3176677
  • File → Import → STL → selected the bird file
  • Applied scale and rotation on import if needed (Ctrl + A → Rotation & Scale)

3. Adjusting and Duplicating the Birds

  • Entered Edit Mode (Tab) on the bird
  • Made minor vertex adjustments to clean up flat/sharp areas (mostly Grab and Proportional Editing O)
  • In Object Mode:
  • Duplicated the bird: Shift + D
  • Scaled duplicates differently (e.g., one at 100%, one at 80%, one at 120%) using S
  • Positioned them on the base plate in an aesthetically pleasing arrangement using G and R

4. Boolean Union – Combining Birds with the Base Plate

  • Selected all bird objects first, then the base plate last (active object)
  • Used Boolean Modifier on the base plate:
  • Modifier Properties tab → Add Modifier → Boolean
  • Operation: Union
  • Object: selected one bird at a time (or used Collection method for multiple)
  • Applied all modifiers one by one (or used a single Boolean with a Collection)
  • Ellen helped troubleshoot non-manifold geometry and incorrect normals (common reason Boolean fails)
  • Fixed by: Edit Mode → Mesh → Normals → Recalculate Outside (Ctrl + N)
  • And Merge by Distance (Alt + M) to remove duplicate vertices

5. Setting Correct Height for the Positive Part

  • Decided: total plywood thickness = 18 mm
    → Positive height = 8 mm base + 10 mm relief
  • Selected the base plate → Edit Mode → selected top face → Extrude → typed 10 mm upward
  • Alternatively: scaled the combined positive in Z only to final desired height, then cut at exactly 8 mm from bottom

6. Adding Volume to Flat/Thin Details

  • Some origami wings and tails were too thin (< 1 mm) → risk of breaking in leather
  • In Edit Mode:
  • Selected flat areas → Extrude (E) a few mm in local normal direction
  • Used Bevel modifier or Ctrl + B on edges to round sharp corners slightly
  • Used Solidify modifier temporarily on thin parts to give them consistent thickness

7. Creating the Negative Part

  • Duplicated the entire finished positive → Shift + D
  • Added a new cube: 200 × 200 × 18 mm (same as step 1)
  • Applied Boolean Difference on the new cube:
  • Add Modifier → Boolean → Operation: Difference
  • Object: selected the positive mold
  • Applied the modifier → this created the cavity
  • Added 1 mm offset for easy demolding and material compression:
  • Added Solidify modifier on the negative:
    • Thickness: −1 mm (negative value pushes walls outward)
    • Offset: 1 (expands the cavity)
  • Or used Transform → Scale with pivot point at bottom + slight manual offset
  • Applied the Solidify modifier

8. Final Cleanup and Export

  • Checked both parts:
  • Edit Mode → Mesh → Clean Up → Delete Loose / Degenerate
  • Recalculated normals again (Ctrl + N)
  • Made sure manifold (no holes): 3D-Print Toolbox add-on → Check All
  • Applied all remaining modifiers and transforms (Ctrl + A → All Transforms)
  • Selected Positive → File → Export → STL → named “Mold_Positive.stl”
  • Selected Negative → File → Export → STL → named “Mold_Negative.stl”
  • Exported with:
  • Selection Only: enabled
  • Scale: 1.0
  • Forward/Up axes: Y Forward, Z Up (standard for Fusion 360)

Files were then sent to Fusion 360 for toolpath generation.

This is the exact sequence and tools you used in Blender to create the final positive and negative mold parts.

Step-by-Step Process in Autodesk Fusion 360 + ShopBot CNC Setup

1. Fusion 360 – Setup and Manufacturing Workspace

Insert Mesh

Open sketch (in Design Mode) Open in sketch and Make sqrs Go from Desing to Manufacture Mode In Setup insert Stock dimensions

In Tools choose Adapteave Clearing function _1,5mm Max Rafing Depth Finishing in Parallel _0,25mm Stepover Cutting with 2D Contour _ 2,5mm Max Rafing Stepdown

  1. Open STL files
  2. File → New Design from File → select positive STL → Insert Mesh
  3. Repeat for negative STL (or place both in the same design if you prefer one file)

  4. Create a new component for Positive and one for Negative.

  5. Create Stock (Material Setup)

  6. Go to MANUFACTURE workspace
  7. Setup → New Setup
  8. Model: select the mesh body (Positive first)
  9. Stock tab → Mode: Fixed size box
    • Width (X): 200 mm + 20–30 mm extra (e.g., 230 mm)
    • Depth (Y): 200 mm + 20–30 mm extra
    • Height (Z): 18 mm (exact plywood thickness)
    • Stock offset: usually +3–5 mm in X/Y for tabs and safe margins

  10. Origin: Select Stock box top / Stock box corner (most common for ShopBot)

  11. Repeat Setup for Negative part (second Setup in the same file or separate file)

  12. Tool Library – Create Tools (typical for plywood)

  13. 6 mm flat end mill (¼" if using imperial bits) – for roughing and cutout
  14. 3 mm flat end mill (or ballnose if you want smoother finish) – for finishing
  15. Material: set to Plywood

2. Generating the 3 Toolpaths (per part – repeat for positive and negative)

Toolpath 1 – Roughing with 6 mm end mill

  • 3D → Adaptive Clearing (best for plywood)
  • Tool: select your 6 mm
  • Geometry: select model + containment boundary if needed
  • Heights: Bottom Height → Model bottom, Top Height → Model top
  • Passes:
    • Optimal Load: 45–55% (2.7–3.3 mm for 6 mm tool)
    • Maximum Roughing Stepdown: 9–12 mm (2–3 passes for 18 mm)
    • Stock to Leave: Radial 0.5 mm, Axial 0.5 mm
  • Linking: High Feedrate for retracts
  • Name: “1_Rough_6mm”

Toolpath 2 – Finishing with 3 mm end mill

  • 3D → Parallel (or Scallop if you prefer)
  • Tool: 3 mm flat or ballnose
  • Geometry: same as above
  • Heights: same
  • Passes:
    • Stepover: 0.25–0.4 mm (8–13% of tool diameter for smooth finish)
    • Direction: 45° or 90° (Parallel strategy)
    • Multiple Depths: Stepdown 3–5 mm
    • Stock to Leave: 0 mm (both radial and axial)
  • Smoothing: enable, Deviation 0.01–0.02 mm
  • Name: “2_Finish_3mm”

Toolpath 3 – Cutout / Parting with 6 mm

  • 2D → 2D Contour
  • Tool: 6 mm
  • Geometry: select the outer silhouette (bottom edge of the model)
  • Heights: Bottom → Model bottom – 1 mm (to cut slightly into spoilboard)
  • Passes:
    • Multiple Depths: Stepdown max 6 mm
    • Tabs: Add 4–6 tabs, width 8–10 mm, height 3–4 mm
  • Enable “Stock to Leave” = 0
  • Name: “3_Cutout_6mm”

Repeat all three toolpaths for the negative part (second Setup).

3. Post-Processing (Generate G-code for ShopBot)

  • In each Setup → Actions → Post Process
  • Post processor: ShopBot OpenSBP (or ShopBot MT if you have newer machine)
  • Output folder: create separate folder like “Positive” and “Negative”
  • Generate one .sbp file per toolpath → you will have 6 files total (3 for positive, 3 for negative)
  • Recommended naming:
    P_1_Rough_6mm.sbp
    P_2_Finish_3mm.sbp
    P_3_Cutout_6mm.sbp
    N_1_Rough_6mm.sbp
    … etc.

4. ShopBot Machine Setup & Running Procedure

Initial Machine Preparation

  1. Turn on ShopBot control box, air compressor (dust collection), start computer.
  2. Open ShopBot 3 software (PartWorks file).
  3. Homing: Click the yellow “Reset” button → Home X, Y, then Z (with metal plate + alligator clip).
  4. Warm-up spindle: Keypad → [SU] Spindle Warm-up routine (15–20 min).

Material and Workholding

  1. Place 18 mm plywood on the table, screw it down in corners (outside working area) or use double-sided tape/vacuum if you have it.
  2. Place spoilboard (MDF sacrifice sheet) underneath if not already there.

First Part (usually Positive)

  1. Load first file: File → Open → P_1_Rough_6mm.sbp
  2. Install 6 mm roughing cutter (collet must be clean!).
  3. Z-Zero:
  4. Move spindle over material
  5. Place Z-zero plate under tool
  6. Click Zero Z button (or [ZZ] on keypad)
  7. X/Y Zero: move to lower-left corner of your stock → Zero X and Y axes (or use [Z2] for two-axis zero).
  8. Start dust collection + wear safety gear.
  9. Preview the cut (3D view) → Click Start.
  10. Run P_1_Rough_6mm.sbp → watch first 30 seconds, then let it run.

Tool Change Procedure (6 mm → 3 mm)

  1. After roughing finishes → spindle stops → turn off dust collection.
  2. Loosen collet → remove 6 mm tool → insert 3 mm finishing tool → tighten firmly.
  3. Re-zero Z ONLY (very important – X/Y stay the same):
    • Place plate again → Zero Z only.
  4. Load next file: P_2_Finish_3mm.sbp → Start.

Final Cutout (back to 6 mm)

  1. After finishing → change back to 6 mm cutter → re-zero Z again.
  2. Load P_3_Cutout_6mm.sbp → Start.
  3. When tabs are cut → carefully pop the part out (use chisel or oscillating tool to cut remaining tabs).

Repeat for Negative Part

  1. Remove finished positive mold.
  2. Place new plywood sheet → screw down.
  3. Repeat steps 7–20 with the N_ (negative) files.

Critical Tips

  • Always re-zero Z after every tool change!
  • Keep X/Y zero the same for all 3 operations of one part (use corner blocks or dowel pins for perfect alignment).
  • Feedrates for plywood (typical safe values):
  • 6 mm roughing: 80–100 mm/sec, plunge 20 mm/sec
  • 3 mm finishing: 60–80 mm/sec
  • Cutout: 50–70 mm/sec
  • Use hearing protection, eye protection, and dust mask.

That’s the complete detailed workflow from Fusion 360 to finished positive + negative mold on a ShopBot. Good luck with your project!

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weekly assignment

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about your images..delete the tip!!

  1. Remember to credit/reference all your images to their authors. Open source helps us create change faster together, but we all deserve recognition for what we make, design, think, develop.

  2. remember to resize and optimize all your images. You will run out of space and the more data, the more servers, the more cooling systems and energy wasted :) make a choice at every image :)

This image is optimised in size with resolution 72 and passed through tinypng for final optimisation. Remove tips when you don't need them anymore!

get inspired!

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Add your fav alumni's pages as references

References & Inspiration

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  • Two images side-by-side

describe what you see in this image describe what you see in this image


  • Image reference

centered image with credits/reference
  • Download reference

Links to reference files, PDF, booklets,

about your images..

  1. Remember to credit/reference all your images to their authors. Open source helps us create change faster together, but we all deserve recognition for what we make, design, think, develop.

  2. remember to resize and optimize all your images. You will run out of space and the more data, the more servers, the more cooling systems and energy wasted :) make a choice at every image :) This image is optimised in size with resolution 72 and passed through tinypng for final optimisation.

Overview material research outcomes

example from the documentation of Loes Bogers TextileLab Amsterdam 2019-20
Biofoam Gelatin foil Bioresin Biosilicone
Starch Rubber Biolinoleum Alginate net Alginate foil
Alginate string Agar foil Bio composite Reused PLA

Tools

Process and workflow

describe what you see in this image

My first step was too..... Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum.

Ingredients & Recipes

Prepare this recipe 1 by collecting the ingredients necessary, to be found in the list below:

=== "ingredients"

    * xxx gr
    * xxx gr
    * xxx gr
    * xxx ml
    * xxx gr

=== "tools"

    * xxx gr
    * xxx gr
    * xxx gr
    * xxx ml
    * xxx gr

=== recipe fishleather and fishskin bio-plastic (food waste)

    * measure - measure - measure
    * add, combine, mix..
    * simmer, cook, boil, freeze, burn, crush...
    * mix, smash, stack, overlay..
    * cast, pour, press..
    * dry, aereate, dehydrate..
    * remove, peel, unmold..
    * finishing touches

Documenting and comparing experiments

TEST SERIE BIO-PLASTIC
Material pic Material name polymer plastifier filler emulsifier
bio-rainbow biokelp powder 12 gr glycerol 100 ml rainbow dust 1 kg green soap a drop
bio-rainbow biokelp powder 12 gr glycerol 100 ml rainbow dust 1 kg green soap a drop
bio-rainbow biokelp powder 12 gr glycerol 100 ml rainbow dust 1 kg green soap a drop
bio-rainbow biokelp powder 12 gr glycerol 100 ml rainbow dust 1 kg green soap a drop
RESULTS

Two ways of showcasing and comparing results with images below

On the left an image of a sample made by xxx with xxx. The dye is more xxx. On the right, an image of a sample made by xxx with xxx and xxx. Here the dye is more xxx.


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Recipes

  1. recipe: salmon skin fish-leather ↩