Theatre Design & Technology - Summer 1999 - 59

meant that each time the router changed direction there was a slight wobble in the cut. Since the pieces
we were cutting out with the router were going to be planed down further during the carving of the deck,
we did not take measures to correct the wobbling.
The whole CNC router assembly was mounted on a 6' x 12', framed-plywood table. In order to keep
the sheets of foam from shifting during cutting, we driUed holes in the tabletop and set up a shop vacuum
underneath, using a concept similar to that of a vacuum-forming table. In one corner of the table, we installed two limit switches which defined the "home" or "0,0" position for the router. These limits provided a consistent, definable point in each drawing that we could easily reference on the table.
In its entirety, it took Rich Gold and Alan Hendrickson only two weeks to plan and build the CNC
router. Perhaps the most interesting part of the whole project was that we built the whole machine out of
parts we had in our shop and theatre. We spent only about $80 on plywood for the table and some
toothed-belt sprockets for the x-axis and y-axis frames. The materials we had at hand, therefore, drove
the design, and not all of the parts were ideal for the function they served. Had we bought all the pieces
from scratch, there probably would have been some changes.
During our build peliod, we had the carpenters cut some of the foanl pieces out by hand and some \\~th
the CNC router. We found it took less tinle to change the lines in the AutoCAD dra\\IDgs to polylines and do the
CAD-to-DMC transfer than it did to layout tile draWings in full scale. Looking back at the project, we estimate
that it only took one carpenter three days to cut out about one tilird of tile total number of pieces using the CNC
router, whereas it took two carpenters almost two weeks to cut out tile otiler two-tilirds by hand. While the use
of the CNC router reduced the number of carpenter build hours, it did increase the amount of managelial time
necessary to prepare tile drawings. Our project required one cutout of a large number of different shapes. Had
it required many cutouts of one shape, the Cl Crouter would have been an even greater asset. .:.

Item

Quantity

Cost per Unit

Total Cost

Servo-Motor

2

$1200

$2400

Servo-Motor Drive Cabinet

2

$800

$1600

Relative Encoder

2

$300

$600

Galil DMC-1502 Motion Controller

I

$1500

$1500

CAD-to-DMC software

1

$600

$600

Gear Reducers

2

$200

$400

Sprockets and Chain

-

-

$80

Steel Shafts and Steel Framing

-

-

$100

Toothed belt

42'

$4.25/ft

$180

Toothed Belt Sprockets

2

$40

$80

"Home" Limit Switches

2

$30

$60

Linear Bearings

2

$70

$140

Cam Followers

6

$30

$180

Vacuum Table (Plywood and framjng) -

-

$70

Shop Vacuum

I

$200

$200

2 hp Porter Cable Router

I

$200

$200

Wire and Connectors

-

-

$200

PC Computer to Download to Galil

I

$1500

$1500

-

$10

Ye" drill bit to use as cutting tool

10

TOTAL COST
T'Z>&T

$10,100
M

.\1

E

R

1 9

9

9

57



Table of Contents for the Digital Edition of Theatre Design & Technology - Summer 1999

Contents
Theatre Design & Technology - Summer 1999 - 1
Theatre Design & Technology - Summer 1999 - 2
Theatre Design & Technology - Summer 1999 - 3
Theatre Design & Technology - Summer 1999 - Contents
Theatre Design & Technology - Summer 1999 - 5
Theatre Design & Technology - Summer 1999 - 6
Theatre Design & Technology - Summer 1999 - 7
Theatre Design & Technology - Summer 1999 - 8
Theatre Design & Technology - Summer 1999 - 9
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Theatre Design & Technology - Summer 1999 - 18
Theatre Design & Technology - Summer 1999 - 19
Theatre Design & Technology - Summer 1999 - 20
Theatre Design & Technology - Summer 1999 - 21
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Theatre Design & Technology - Summer 1999 - 25
Theatre Design & Technology - Summer 1999 - 26
Theatre Design & Technology - Summer 1999 - 27
Theatre Design & Technology - Summer 1999 - 28
Theatre Design & Technology - Summer 1999 - 29
Theatre Design & Technology - Summer 1999 - 30
Theatre Design & Technology - Summer 1999 - 31
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https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1970May
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1970Feb
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1969Dec
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1969Oct
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1969May
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1969Feb
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1968Dec
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1968Oct
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1968May
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1968Feb
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1967Dec
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1967Oct
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1967May
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1967Feb
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1966Dec
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1966Oct
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1966May
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1966Feb
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1965Dec
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1965Oct
https://www.nxtbook.com/nxtbooks/hickmanbrady/tdt_1965May
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