Updated MPCNC Brushed Motor Foam (Needle) Cutter

Although this brushed motor version of the MPCNC (https://www.v1engineering.com) foam cutter (needle cutter) is basically obsolete, I had an extra motor lying around, so created this updated mount to work with the latest version of the CNC (as of 10/27/18). The foam cutter mount I remixed this from only worked with the old MPCNC.

It is basically a combination of the mount for the DW660 spindle (https://www.thingiverse.com/thing:944952) and this foam cutter attachment (https://www.thingiverse.com/thing:1138627)

So far it has fabulously cut the Flite Test Tiny Trainer (RC airplane) out of foam board!

Other parts you'll need:

• DC Motor- http://a.co/d/3nLCnRc
• Speed Controller - http://a.co/d/26Qb5L7
• 12V 2A Power Supply - http://a.co/d/csnfPDe
• Power Cable Extender (optional) - http://a.co/d/iwqKPN8
• Needle (Music Wire) - https://www.amazon.com/dp/B01L6SMWL4/ref=cm\_sw\_em\_r\_mt\_dp\_U\_0lMSCb86H9WX0
• Cutter Guide - http://a.co/d/0CylW9h
• Various M3 Nuts and Bolts
• Zip-ties

Electrical Wire Brushless motor version (better performance): https://www.thingiverse.com/thing:1723915

More information on Flite Test: https://www.flitetest.com/articles/cutting-foam-sheets-with-a-needle

A simple calculator I made to help you set the correct feed rates on your CNC for optimal cutting: https://docs.google.com/spreadsheets/d/1RUaiQwKQ7Q1XIC2zub7H61wZxmpIkNF7Hz3bQUPInNQ/edit?usp=sharing

Print Settings

Rafts:

Doesn't Matter

Supports: 

Yes

Resolution:

Mount = 0.3mm - Wheel = 0.2mm

Infill: 

25%

Filament:

PLA

Print Time: 

Mount - 4 hours, Wheel - 20 minutes

The Amazing MPCNC!

The MPCNC (Mostly Printed CNC) is an amazing project by Alted from V1 Engineering! It's amazing how versatile and inexpensive the machine is. Check out his website and Thingiverse link: https://www.v1engineering.com/rnhttps://www.thingiverse.com/thing:724999rn

Change Log

10/27/2018

Initial release.

11/22/2018

Improved flywheel.rn- I've been getting jagged cuts, and my needle has been snapping. To fix this, I've reduced motor voltage, added oil/grease, and shortened how far the needle comes out of the end of the bicycle valve (only 1.25x material depth). As another fix, I've redesigned the flywheel to be much smaller and reduced its thickness to stop the wire from scraping excessively on the bicycle valve.

11/25/2018

Flywheel improvement (again!).rn- Further decreased the size of the wheel and moved the hole (where the needle mounts) closer to the center so as to reduce the depth of the cuts (which are currently too deep).

11/25/2018

Improved mount.rn- Tweaked various hole sizes, increased the strength/robustness, and made the device more compact.

11/30/18

Refined mount and slightly adjusted flywheel.rn- Slightly increased the shaft diameter in the flywheel and refined the mount to include a slot for the speed controller.

12/9/18

Minor design refinements on the wheel and mount.

5/27/19

Slight adjustments to the wheel to prevent it from scraping against the motor housing while in motion.