Get CNC precision without a CNC machine?

[swbluto]

Hello, I'm looking to design some metal parts using my computer and I was wondering if there were ways to precisely make metal parts without buying a $2000-$3000 CNC machine. Does anybody know of any other methods or tools to do the job?

Thanks!

 

[amberwolf]

A manual lathe and/or mill can do it, but you must learn how to operate it with precision, as the computer won't be able to.

You can also build your own CNC; there are a number of open-source projects out there to do it.

It can also be done with hand tools, if you frequently check your work with precision measuring instruments. But I imagine that would be extremely tedious and time consuming. :lol:

 

[kfong]

It is possible to build a CNC from cheap imported mills, but you need to be aware that tooling cost can add up and it would be something you would have to be committed to. The learning curve for the CAD stuff and all the rest of the software to create the cut files was to me the hardest part of the CNC process. Creating the CNC was the easy part in comparison. What you end up with is priceless though. I find all kinds of uses for my acquired CNC skills.

If you have patience, even hand tools can grind away at metal to be accurate enough for most ebike parts. There have been plenty of excellent builds here by members with minimal power tools.

 

[jonathanm]

Yes, you will find that the cnc part of a mill can be the cheap part. the expensive bit is the cutters, tooling, jigs and part holding. You still need all this to do it manually, plus the skill obviously.

 

[Tommy]

IMO CNC Mills or Lathes are best suited for making lots of the same parts, not the case(most times) when home building projects for personal use.
today we have digital calipers, micrometers and linear scales that lets even a weekend builder make high procession parts with manual machines,
or even hand tools.

with a little programming skills you could even use your web cam and monitor for measuring, modeling and laying out bike frames and components.


Tommy

 

[ions82]

Hello, I'm looking to design some metal parts using my computer and I was wondering if there were ways to precisely make metal parts without buying a $2000-$3000 CNC machine.!

If you're LUCKY, you can find a running CNC machine for $2,000-3,000. However, I'm guessing you wouldn't be able to move, power, and program a 3,000+ pound machine. There's a reason that people make a career out of cutting metal. Despite what high school guidance counselors might suggest, PROPERLY cutting metal isn't for morons. If you can do all the programming/drawing, you might be able to find a local shop that will do it for a reasonable price. Just don't go into a shop expecting them to make parts for $10-20. Most likely, they'll be running machines that cost at least $80,000.

 

[fechter]

What do you think they used before computers? Lots of precision parts were made before the '80s the good old fashioned way with dial gauges and hand drive.

Depending on the thickness of material you're planning to cut, I've seen cheap CNC setups for Dremel grinders.

 

[Hillhater]

IMO CNC Mills or Lathes are best suited for making lots of the same parts, not the case(most times) when home building projects for personal use.

+1
With a good quality hand tools..a Hacksaw, File and Drill (power), etc ..and a solid bench vice.... a SKILLED person could make most parts for an Ebike. ....
..And if you read some of the threads on here you will see how its done.

 

[docnjoj]

Definitely check out Aussiejesters build threads as I do not believe he uses computer controlled mills. He does his stuff by hand and it is quite excellent!
otherDoc

 

[AussieJester]

IMO CNC Mills or Lathes are best suited for making lots of the same parts, not the case(most times) when home building projects for personal use.

+1
With a good quality hand tools..a Hacksaw, File and Drill (power), etc ..and a solid bench vice.... a SKILLED person could make most parts for an Ebike. ....
..And if you read some of the threads on here you will see how its done.

+3 CNC is best for multiple items...

Definitely check out Aussiejesters build threads as I do not believe he uses computer controlled mills. He does his stuff by hand and it is quite excellent!
otherDoc

Correct Doc :wink: all my stuff is done with combination of a 6inch angle grinder, air die grinder, hand files a bench drill and a linisher, no (working) cncs here yet, although i do have one half built, just need to finish the thing and get ES member local to me MrDanny Mayes to help me learn how to use CAD, more likely ill just finish the mill and let D-MaN do the design side of things i prefer the hands on approach much more than watching a machine do it haha...

But yes, if you are patient and have better than average hand eye co-ordination you can make some great parts
check also Timma2500 builds he has only a bench drill he hand files all his stuff and when you see it you will be blown away takes him days to make some of the parts on his Norco...

Best of luck with it anyway

KiM

 

[PHC]

I use emachineshop.com free software to design my 2D parts. It has bend modeling and 3D preview. You can print the drawing out 1:1 on an inkjet or laser printer and then spray glue the back side and stick it to your sheet metal. Then use a straight edge and a scribe to etch the cut lines into the metal. Don’t etch bend lines because this will cause cracks when you bend the metal. I use this method for all my "one off" prototype parts. There are a lot of creative folks on the "home built stabilizer" HBS board making amazing precision parts that look like CNC parts. Have a look at their techniques.

http://hbsboard.com/

http://emachineshop.com

Paul

 

[Thud]

A little simple geometry & some decent drafting tools will lay out very acurate bolt circles & divisions...the rest is all about how close you cut to the lines...here is a simple top hat adapter ISO disc brake pattern to 5.25" kart sprocket.

lay out the critical points & bore & tape them ( a 6 bolt pattern spacing = the radius of the circle)
once you have that draw a pattern of crap you need removed, drill a series of holes close to the line & have at it with a $7 coping saw

I got lazy with the file & grabbed the die grinder & a big burr to smooth it out

finished part:

back side: