CNC Router Bar Stool

In this Instructable you will:

• Setup the CNC Router

• Load a DXF file and generate the G-CODE the machine will use to cut out the stool

• Cut out a bar stool using the CNC Router

Step 1: Gather the Supplies

You will need:

• CNC Router and controlling computer with Cut 2D and Mach 3

• Stool DXF file

• 0.25-inch End mill (2 flute)

• 4-foot by 3-foot piece of 0.703-inch thick plywood

• "CNC Collet Nut" Wrench (or Adjustable Crescent Wrench)

• 21mm Wrench (or Adjustable Crescent Wrench)

• Screwdriver and screws

• Safety glasses

• Hearing protection (optional, but recommended)

• Tape measure (optional, but recommended)

Step 2: Load DXF

1. Use DXF file
   

2. Open Cut 2D (Picture 1)

3. Click "Open an existing file" (Picture 2)

4. Select "CNC Drawing for one 0 stool.DXF" (Picture 3)

5. The "Job Setup" page will load (Picture 4)

1. Adjust size of wood (width = 48 inches, height = 36 inches)

2. Adjust thickness (0.7 inches)

3. Uncheck "Use origin offset"

4. Click "OK"

Step 3: Join Vectors

The imported DXF will be a series of unconnected lines and curves. (Picture 1) You will want to join the vectors to create closed objects.

To do this:

1. Type "j" on keyboard

2. The "Join Vectors" menu will appear on the left (Picture 2)

3. Select all of the objects on the sheet by clicking and dragging a box around them

4. Click "Join" in the "Join Vectors" menu on the left

There should now be 8 closed vectors which you can select by clicking on them. (Picture 3) We will use these vectors to create toolpaths in the next step.

Cut 2D Tip:

You can click and drag down and right to select only the objects within your selection window. You can click and drag up and left to select all objects touching or inside of your selection window.

Step 4: Create Toolpaths

Step 5: Output G-CODE

We will now create the code that the machine will use to cut out the stool.

1. Click the 5th button in the second row of the grid in the toolpaths menu: "Save toolpaths" (Picture 1)

2. Select all the toolpaths in the upper right list (Picture 2)

3. Make sure "Output all visible toolpaths to one file" is selected

4. Make sure Mach2/3 is selected as the post-processor

5. Click "Save toolpath(s) to file"

6. Pay attention the the place and name you are saving the file, and click "Save"

Step 6: Load Plywood

1. Move gantry out of the way
   

1. If stepper motors are powered up, use Mach 3 (details in Step 8: Load G-Code in Mach 3)

2. If stepper motors are not yet plugged in, you may gently push it by hand

2. Set plywood on top of spoils board. Be sure to line up the edges of the plywood with the edges of the spoils board.

3. Screw plywood into spoils board at edges.

Step 7: Insert the End Mill

Step 8: Load G-CODE in Mach 3

Step 9: Set Up CNC Router and Begin Cutting

1. Unplug spindle motor, water pump, and stepper motor power

2. Turn off the sawdust collection vacuum

3. Remove the cut stool pieces

4. Remove remaining scrap from CNC Router table

5. Vacuum all surfaces

6. Remove end mill

7. Put all tools away

8. Close computer programs and delete your files from the desktop

9. Sand the edges of the stool pieces

10. Assemble the pieces

11. Screw in the footrest (and seat if necessary)

12. Enjoy your new stool!