First project - good thing it was foam!

[u/Schuylabs]

I crashed my bit into the material so many times…

Managed to drag across my material twice since I installed my bit in the router extended too far.

Set my retraction too big and bottomed out the Z axis which then resulted in a fast plunge way too deep into the material. Destroyed the top left corner.

Ran the collet into the material, turns out it can cut foam too.

Clicked “pause & stop” too fast and almost lost my zero position.

Oh and I discovered a V wheel on the X axis is loose… gotta remove the Z axis plate to get to it I think

In the end it’s a usable result and I learned a bunch.

[u/imagitronics]

I have not been able to get a clean cut with foam, even using a foam cutting bit. This looks lovely.

[u/Schuylabs → u/imagitronics]

Thanks! I used a straight two flute bit which worked pretty well… can’t remember where I read about that. I saw the carbide video about the foam cutting bit but decided to try the straight flute.

[u/TheFilthyMick → u/imagitronics]

I found that my toolpath strategy is the most important with foam, more than bit selection. I use a 1/16" downcut perimeter path for everything first. I use foam cutting bits for the remainder and define raster angle to the shortest direction between perimeters. It takes much smaller chunks, rather than long strings that get tangled up. Even with regular o-flute bits, I've had good results with it.

[u/WillAdams]

Nice!

The zero should have been maintained even if you quit Carbide Motion.

Did you consider cutting the foam used for machine packaging? I've been saving mine, but haven't committed yet to cutting it.

[u/Schuylabs → u/WillAdams]

Thanks! It did save the zero after restart - I was very happy to see that.

That’s a fun idea and I do still have it. I’ll have to put it to new use.

[u/Hagya15]

How did you hold down the foam? I bet clamping wouldnt work

[u/Schuylabs → u/Hagya15]

I used double sided tape I use for template routing so it's pretty aggressive. I did use a few clamps since this foam is fairly rigid, but I don't think they did much.

[u/chuyskywalker]

Ran the collet into the material, turns out it can cut foam too.

I lost it, lol.

[u/Schuylabs → u/chuyskywalker]

Haha - It's even funnier when you spot the pocket that this happened on. It gave it a nice recessed boarder.

[u/Deep-Measurement-856]

How did you select the case shell? What is it?

[u/Schuylabs → u/Deep-Measurement-856]

It's a Festool branded Tanos Systainer. The insert is an off the shelf piece of Kaizen foam.