PLIERS WORK SURFACE CUTTING MAT MARKING TOOLS ...

ILAN E. MOYER
WORK SURFACE
Find a sturdy table that is in a
well-lit area. Ideally you’ll be
working with 40” x 30” sheets, so
a suitably sized surface will help.
CUTTING MAT
A large piece of cardboard will
do, but I would highly recommend
a cutting mat. Mine is
18”x24” and made by Artool.
MARKING TOOLS
I use an ultra �ne point black
Sharpie, but if you’d prefer, a
pencil and eraser will work as
well.
CIRCLE STENCIL
The two hole diameters which
you’ll need to mark are 5/8” and
1-1/8”. A compass will work just
as well.
COMPASS
A substitute for the circle stencil.
> 16” RULER
Highly recommended. A 24”
C-Thru ruler will make your life
much easier. Make sure that it
has 1/16” markings throughout.
RIGHT TRIANGLE
These instructions are designed
to take advantage of the
factory-square edges of the
foamcore. This tool is optional.
SHEET 1/15
RAZOR KNIFE
I highly recommend getting an
Olfa knife. It is di�cult to cut 1/2”
foamcore with just an Exacto.
WIRE CUTTERS
These will be important for
cutting thin steel cable and
stripping the stepper motor
wires.
PLIERS
A needle-nose or any other
variety will work well.
SMALL WOOD SAW
If you want to save money and
use wooden dowels, you’ll need
this to cut them to length. A real
saw works even better.
12” METAL RULER*
I cut everything freehand, but if
you’re bad at cutting straight
lines or want to better protect
your �ngers, grab one of these.
HOT GLUE GUN
Mine is made by Surebonder and
has both a high and low
temperature setting. I run it at
high.
SCREWDRIVER
You’ll need a medium sized �at
head screwdriver.
066 FOAMCORE CNC: VISUAL TOOL GLOSSARY 3/17/2011

OR
+
ILAN E. MOYER
ALUMINUM SHAFTS
These shafts are made to be very straight with
highly accurate diameters. They are responsible
for both moving and guiding the toolhead and
the Z axis table. 1/2” diameter x 15” long.
QTY: 3 $9.00 EA, $27.00 TOTAL
McMaster-Carr P/N 1031K14
NYLON BUSHINGS
Molded plastic sleeves which are designed to
slide on precision shafts. They provide a
low-friction bearing for the moving parts of the
machine. 1/2” inner diameter.
QTY: 2 PACKS $3.15 /PK, $6.30 TOTAL
McMaster-Carr P/N 6389K623
CONSTANT-FORCE SPRING
This tape-measure-like spring unravels with
consistent force, making it ideal to counter the
weight of the Z -axis table and to reduce the load
on the Z-axis stepper motor.
QTY: 1 $5.17 EA, $5.17 TOTAL
McMaster-Carr P/N 9293K44
DELRIN STRIP
Thin strips of delrin, an engineering-grade
plastic, are used to to reinforce the foamcore in
places where it might dent or wear.
QTY: 20 FT $0.39 /FT, $7.80 TOTAL
McMaster-Carr P/N 2638T11
WOODEN DOWELS
If you have the ability to cut them, wooden
dowels are a cheap and e�ective alternative to
steel dowel pins. Purchase at least 18” of both
1/4” and 1/2” diameter wooden dowel.
~$3.00 TOTAL
Local Art Supply Store
STUBBY STEEL DOWEL PINS*
These pins will get the job done, but are
expensive so search for alternatives �rst. If you
can’t use wooden dowels, you’ll need to �nd or
create cylinders which are 1/2” dia. and 1” long.
QTY: 2 PACKS (20) $6.65/PK, $13.30 TOTAL
McMaster-Carr P/N 98381A710
SLENDER STEEL DOWEL PINS*
These pins will get the job done, but are
expensive so search for alternatives �rst. If you
can’t use wooden dowels, you’ll need to �nd or
create cylinders which are 1/4” dia. and 2” long.
QTY: 1 PACK $8.85/PK, $8.85 TOTAL
McMaster-Carr P/N 90145A549
HOSE CLAMPS
Typically used to secure hoses to �ttings, we will
use hose clamps as simple tensioning mechanisms
for the steel cables.
QTY: 1 PK $7.01/PK, $7.01 TOTAL
McMaster-Carr P/N 5388K22
STEPPER MOTORS
These easily controlled motors will move the
toolhead around with some degree of precision.
The type depends on your controller, but I will be
using unipolar motors with a step angle of 0.9°.
QTY: 3 $6.95 EA, $20.85 TOTAL
Alltronics P/N 28M053
WIRE ROPE
SHEET 2/15
The motion system of the machine relies on what
is called the “capstan e�ect.” This �ne braided
steel cable will prevent the aluminum shafts from
spinning without also rolling.
QTY: 25 FT $0.41/FT , $10.25 TOTAL
McMaster-Carr P/N 8930T22
DOUBLE-STICK TAPE
An adhesive-paper-adhesive sandwich.
Double-stick tape is used to laminate the delrin
strips to the foamcore, as well as generally to
stick things together.
QTY: 1 ROLL $7.93 /ROLL, $7.93 TOTAL
McMaster-Carr P/N 76405A13
ELECTRICAL TAPE*
Any color will do. This �exible and somwhat
stretchy tape will be used to couple the motors to
the aluminum shafts, as well as to insulate wiring
connections.
Local Hardware Store
POLYESTER TAPE
I really like this plastic-backed adhesive tape, but
you could get by with masking tape or clear tape.
It is used as a general tape wherever necessary.
QTY: 1 ROLL $6.81 /ROLL, $6.81 TOTAL
McMaster-Carr P/N 7630A42
FOAMCORE!
You’ll need a 40” x 30” sheet of 1/2” thick
foamcore, and a 30” x 20” sheet of 1/4” thick
foamcore. Several smaller sheets can be used
instead of a big sheet - check the cut patterns.
~$13.00
Local Art Store
ALUMINUM SPACER
These spacers coincidentally have the right
inner and outer diameters to adapt the 5mm
motor shaft to the 1/2” aluminum shafts.
QTY: 3 $1.54 EA, $4.62 TOTAL
McMaster-Carr P/N 92510A745
SUPERGLUE*
Any super glue will do, although the thinner the
better. I use this awesome 5cP glue, but 100cP
would be OK too. (cP is a measure of �uid
viscocity.)
Local Hardware Store
TOTAL MATERIAL COST: $119.74
* These are either household items or alternative parts
and are not included in the calculated parts price.
066 FOAMCORE CNC: VISUAL BILL OF MATERIALS (BOM) 3/17/2011

Your Order
Date
Purchase order
Order created by
Ship to
3 Ames Street
East Campus, #358
Cambridge, MA 02142
Attention: Ilan Moyer
Shipping method
Ground
March 20, 2011
Ilan Moyer (imoyer@mit.edu)
Send invoice to
imoyer@mit.edu
Payment method
Line Quantity Item Ships Unit price Total
1 3 each 1031K14 Precision Ceramic-Coated Aluminum Shaft 1/2" Diameter,
15" Length
2 2 packs 6389K623 Nylon Bearing Flanged, for 1/2" Shaft Dia, 5/8" OD, 1/2"
Length, packs of 5
3 1 each 9293K44 Stainless Steel Constant-Force Spring 4000 Cycle Life,
.005" Thick, 17" L, .312" Wide
http://www.mcmaster.com/OrdPad/OrdPadPrt.aspx?ordid=842514571442&time=1300664355278
Monday morning $9.00 each 27.00
Monday morning $3.15 pack 6.30
Monday morning $5.17 each 5.17
4 20 ft. 2638T11 Black Delrin Strip .020" Thick, 1" Width Monday morning $.39 ft. 7.80
5 2 packs 98381A710 Alloy Steel Dowel Pin 1/2" Diameter, 3/4" Length, packs
of 10
6 1 pack 5388K22 Worm-Drive Hose Clamp W/Zinc Pltd Steel Screw 11/16"
to 1-1/4" Clamp Dia Range, 5/16" Band Width, packs of
10
7 25 ft. 8930T22 Commercial Grade Nylon-Coated SS Wire Rope 7X7
Strand Core, .018" - .024", 40# Break Strg
8 1 roll 76405A13 Masking Tape - Adhesive on Both Sides for General
Purpose, 1" Wide X 36 Yards Long
9 1 roll 7630A42 High-Temp Polyester Masking Tape 1" Wide X 18 Yards
Long
10 3 each 92510A745 Aluminum Unthreaded Round Spacer 1/2" OD, 1/2"
Length, #10 Screw Size
11 1 pack 90145A549 18-8 Stainless Steel Dowel Pin 1/4" Diameter, 2" Length,
packs of 10
Monday morning $6.65 pack 13.30
Monday morning $7.01 pack 7.01
Monday morning $.41 ft. 10.25
Monday morning $7.93 roll 7.93
Monday morning $6.81 roll 6.81
Monday morning $1.54 each 4.62
Monday morning $8.85 pack 8.85
Merchandise total $105.04
Applicable shipping charges and tax will be added.
Phone (609) 689-3000 Fax (609) 259-3575 Internet www.mcmaster.com Email nj.sales@mcmaster.com
3/20/11 7:39 PM
Page 1 of 1

MATERIAL: 1 /2” FOAMCORE
0”
1 1 /2”
2 1 /4”
12 1 /4”
13”
14 1 /2”
0”
1 1/2”
2 1 /4”
NOTE: SAVE THIS INTERIOR PIECE BECAUSE IT
BECOMES THE MACHINE’S WORK TABLE.
SHEET 3/15
SKETCH LINE
CUT LINE
ILAN E. MOYER 066 FOAMCORE CNC: TOP PLATE AND TABLE CUT PATTERN
3/12/2011
12 1 /4”
13”
14 1/2”

MATERIAL: 1 /2” FOAMCORE
0”
3 /16”
1 3 3 /4”
1”
1
/4”
1 /8”
11 3 /4”
12 1 /2”
13 1 /2”
1”
5 /8”
3 /8”
0”
3 1/2”
4 1/2”
6”
6 3/4”
7
7”
1/2”
7 3/4”
8 1/2”
SHEET 4/15
SKETCH LINE
CUT LINE
ILAN E. MOYER 066 FOAMCORE CNC: BACK PLATE CUT PATTERN
3/12/2011
10”
11”
13 1/2”
13 7/8”
14 1/8”
14 1/2”

MATERIAL: 1/2” FOAMCORE
0”
1 1 /2”
13”
14 1 /2”
0”
1 1/2”
SHEET 5/15
SKETCH LINE
CUT LINE
ILAN E. MOYER 066 FOAMCORE CNC: BOTTOM PLATE CUT PATTERN
3/12/2011
13”
14 1/2”

MATERIAL: 3 /16” FOAMCORE
0”
3 /8”
5 /8”
1 11 /16”
1 1 /2”
5 /8”
3 /8”
0”
9 3 /8”
7 11 /16”
6”
4 1 /2”
3”
1 1 /2”
0”
0”
0”
3/16”
3 /16”
WIDE LEG
NARROW LEG
TILING PATTERN
SHEET 6/15
SKETCH LINE
CUT LINE
ILAN E. MOYER 066 FOAMCORE CNC: LEGS CUT PATTERN
3/12/2011
13 1/2”
13 1 /2”
QTY 2
QTY 4

1 /2”
1 /2”
0”
1”
1 1 /2”
TOP PLATE
EDGE STRIPS
QTY 4
3”
BACK PLATE
EDGE STRIPS
QTY 6
TOTAL SPLIT LENGTH: 73.5”
TOTAL FULL LENGTH: 125”
OVERALL LENGTH: 198.5”
Total split length is the total length of
1” wide delrin strip which needs to be
halved along its length. Total full length
is the total length of delrin strip which will
retain its original width of 1”.
0”
1 /2”
1”
0”
1 /2”
1”
0”
1 /2”
1”
1”
1”
1”
0” 0”
0”
TOP PLATE LARGE STRIPS
TOP PLATE SMALL STRIPS
BACK PLATE STRIPS
SHEET 7/15
SCORE LINE
CUT LINE
ILAN E. MOYER 066 FOAMCORE CNC: DELRIN STRIPS CUT PATTERN
3/18/2011
10”
11”
10 3/4”
SPLIT
QTY 2
FULL
QTY 8
11 1/2”
SPLIT
QTY 2
FULL
QTY 2
SPLIT
QTY 2
FULL
QTY 2

TOP PLATE
EDGE STRIP
TOP PLATE
EDGE STRIP
TOP PLATE LARGE STRIP - FULL
TOP PLATE LARGE STRIP - SPLIT
FRONT OF MACHINE
BACK OF MACHINE
TOP PLATE LARGE STRIP - SPLIT
NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16”.
SHEET 8/15
ILAN E. MOYER 066 FOAMCORE CNC: TOP PLATE DELRIN STRIP PLACEMENT - OUTSIDE SURFACE
3/19/2011
TOP PLATE SMALL STRIP - SPLIT
TOP PLATE
EDGE STRIP
TOP PLATE
EDGE STRIP

TOP PLATE
EDGE STRIP
1 /2”
3 /16”
TOP PLATE
EDGE STRIP
TOP PLATE SMALL STRIP - SPLIT
3 /16”
TOP PLATE SMALL STRIP - FULL
FRONT OF MACHINE
BACK OF MACHINE
TOP PLATE SMALL STRIP - FULL
NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16”.
SHEET 9/15
ILAN E. MOYER 066 FOAMCORE CNC: TOP PLATE DELRIN STRIP PLACEMENT - INSIDE SURFACE
3/19/2011
3 /16”
TOP PLATE SMALL STRIP - SPLIT
TOP PLATE
EDGE STRIP
TOP PLATE
EDGE STRIP

BACK PLATE
EDGE STRIP
BACK PLATE
EDGE STRIP
BACK PLATE STRIP - SPLIT
BACK PLATE
EDGE STRIP
TOP OF MACHINE
BACK PLATE STRIP - FULL
BACK PLATE
EDGE STRIP
SHEET 10/15
ILAN E. MOYER 066 FOAMCORE CNC: BACK PLATE DELRIN STRIP PLACEMENT - INSIDE SURFACE
3/19/2011
BACK PLATE STRIP - FULL
BOTTOM OF MACHINE
NOTE: GAP BETWEEN HALVES OF SPLIT STRIPS SHOULD BE CONSISTENT AND APPROXIMATELY 1/16”.
BACK PLATE STRIP - SPLIT
BACK PLATE
EDGE STRIP
BACK PLATE
EDGE STRIP

BACK PLATE
EDGE STRIP
BACK PLATE
EDGE STRIP
BACK PLATE STRIP - FULL
BACK PLATE STRIP - FULL
BACK PLATE
EDGE STRIP
BACK PLATE STRIP - FULL
TOP OF MACHINE
BACK PLATE
EDGE STRIP
BOTTOM OF MACHINE
SHEET 11/15
ILAN E. MOYER 066 FOAMCORE CNC: BACK PLATE DELRIN STRIP PLACEMENT - OUTSIDE SURFACE
3/19/2011
BACK PLATE STRIP - FULL
BACK PLATE STRIP - FULL
BACK PLATE STRIP - FULL
BACK PLATE
EDGE STRIP
BACK PLATE
EDGE STRIP

FRONT OF MACHINE
BACK OF MACHINE
WIDE
LEG
NARROW
LEG
1 /2”
NARROW
LEG
FRONT OF MACHINE
TOP VIEW
BACK OF MACHINE
BACK PLATE
NARROW
LEG
SHEET 12/15
ILAN E. MOYER 066 FOAMCORE CNC: STRUCTURAL ASSEMBLY GUIDE
3/19/2011
1 /2”
WIDE
LEG
NARROW
LEG

MATERIAL: 3 /16” FOAMCORE
0”
1 /4”
1 /2”
2”
3”
4”
5”
0”
3 /4”
2 1/4”
2”
3”
5 /8”
SHEET 13/15
SKETCH LINE
CUT LINE
ILAN E. MOYER 066 FOAMCORE CNC: TABLE STRUT CUT PATTERN
3/12/2011
QTY 2
13”

MADE FROM DELRIN STRIP MADE FROM 3/16” FOAMCORE
1 /2”
1 /2”
3 /16”
3 /16”
QTY 2
QTY 4
QTY 2
QTY 1
1”
1 1 /4”
2”
3”
LAMINATED WITH ADHESIVE
UNLAMINATED
SHEET 14/15
CUT LINE
ILAN E. MOYER 066 FOAMCORE CNC: Counter Spring and Table Miscellaneous Pieces
3/20/2011
1 /2”
QTY 3
1 1 /4”

1 7 /16”
0” 0”
4”
0”
1 1 /8”
1 1 /2”
BACK PLATE
MATERIAL: 3/16” FOAMCORE
QTY 3
1 /2”
3 /4”
3 ”
SHEET 15/15
SKETCH LINE
CUT LINE
ILAN E. MOYER 066 FOAMCORE CNC: STEPPER MOTOR MOUNTS
3/20/2011
1 11 /16”
2 5 /16”
4”
0”
BEARING STRIPS
MATERIAL: DELRIN STRIP, LAMINATED WITH ADHESIVE
QTY 12
3 /4”
1 7/16”
SIDE PLATE
MATERIAL: 1/2” FOAMCORE
QTY 6
NOTE: IF POSSIBLE USE A FACTORY-CUT EDGE OF
THE FOAMCORE SHEET FOR THIS SURFACE.