When I lent my services to a collegue who was working on a film about 12 years ago, I was introduced to the world of cnc. I remember watching this huge machining centre milling out a slab of mdf and turning it into a fantastic set of gears. I knew that it would have taken me hours to achieve the same thing with traditional power tools. I decided then that I would invest in a cnc router for my own business Oxenham Design. At that time I could turn on a computer, but even to check email seemed like a crazy set of operations. I persevered and learned every piece of relevant software I could get my hands on. I am now fortunate enough to be using Vectric's ASPIRE software, and Techno cnc routers, which has helped us to create some amazing projects, both in part, or in full. I thought that this blog would be a great place to share "behind the scenes" adventures with the software, materials and equipment we use, as well as the projects we build.

Wednesday, 20 August 2014

Sony/ Playstation Counterspy Released!

Finally, the Counterspy game from Sony/ Playstation has released! Not that I'm a video gamer at all, it just means that the NDA on that build is over, and I can post about it!

This is a brief synopsis from the Playstation Store:

 Combining the spy mythology and bold aesthetics of the 1950's and 1960's and set during the Cold War, CounterSpy™ focuses on the rogue third spy agency, C.O.U.N.T.E.R., that keeps the world's super powers at bay. Just as each side of the ongoing conflict gets close to unleashing a blow of earthshaking proportions, C.O.U.N.T.E.R. jumps into action, stealthily sabotaging their dastardly plans and deceptively maintaining world peace.

Sounds kinda cool to me!

We were actually sent a hi-poly 3d model of the main character "Agent Chevalier"
I was totally pumped to build this! I have a love affair with the "low-polygon" style, so this was right up my alley. It was pretty sweet that they supplied the 3d model already in his final pose, saving us the workload of posing the character!

One of my other closet passions is finding the right software that can make our lives easier! I spend a great deal of time online, downloading software, running trial versions, blah, blah. All in attempts to find packages that will ultimately serve us for the better. One amazing little gem is "STL Slicer" This originally came as a plug-in for the Carvewright cnc software. But I feel single hand-idly responsible for contacting them, relentlessly, and getting them to release it as a standalone application. Which they did! WOO-HOO!

The beauty of this simple application, is that it lets you slice 3d STL files with a cut plane. Ultimately making a model like this better suited for 3d CNC machining. The best part of this package is the drag and drop model tree. Simply meaning, that if I slice a model incorrectly, I can drag the parts together, and they self-heal, like it was never cut at all!

The software is dead simple to use, and the interface isn't crowded with features most people would never use.
Another well thought out feature, is that the software will highlight in blue, any surface that becomes an undercut after the slice. This would be based off 90 degrees to the giant green cutplane. They also allow you to adjust this undercut display from 0 to 9 degrees. This is important when using tapered ball nose cutters. I used a straight ballnose cutter for machining, so I just left this setting at 0. I cant stress what a great feature this is, as it let's you decide if you might be better picking a new slice location. However, if you mess it up, you can just drag the pieces together in the model tree, and start over!
As great as the software is, it still doesn't do it for you! So this meant a full day of slicing for me. I fancy myself as being a pretty smart cat, but sometimes I would get myself backed into a proverbial corner. Ultimately having to re-think my slicing strategy, to allow the most efficient, and cleanly machined parts at the cnc end. We had to stay true to the geometry, and this means as little hand shaping as possible after the routing!

As Sony wanted to see a sample finish of just the head, it was the first part of the model sent to the guillotine! Both the sample and the final head were sliced the same way. I was able to get the head down to 3 pieces, the face, and two halves. This was the smallest amount of pieces, with next to no undercuts.
All said and done, there were 23 final pieces, ready for import into Aspire. We're making 2 of these guys, so it was actually 46 pieces to machine!


Tuesday, 5 August 2014

Dead is heading out!

Jody and I got to enjoy the Canadian long weekend, which was a lot fun for us. It did make me a little late posting the tombstone final build though!

 Once our scenic mud had dried (or almost) we spent a bit of time removing some of the texture. As great as I though it looked, it was a little too pitted to pass as a real limestone headstone!

I used Aspire and our Techno to V-carve the text portion onto the front side of the stone. This was done with a high spindle speed, and low feed rate. I didn't want the thin coating on the styrofoam to chip out. A little was okay, but too much would have been very bad for this! In the end, it came out as perfect as I was expecting.

We used 2 coats of the same color glaze to add a little depth to the otherwise flat finish.
The final step was to add 2 gentle passes of speckle paint to all the faces in a very dark grey.

I couldn't help setting up on the lawn at the shop for a couple of quick pictures! I really wish it could have been old, and dripping with weathering, but the script called for a brand new stone :(
It looked really good, and surprised the neighbor when I asked for help lifting it onto the table!

All in all, it was a fun 2.5 day build!
I'm already drawing up different versions for everyone on my 'list' MU-HA-HA!

Tuesday, 29 July 2014

Tombstone Tuesday!

Henceforth, the establishment decrees, that this day of July the 28th, in the year of our Lord two thousand and fourteen, shall forever be known as "Tombstone Tuesday"

Yup.....There it is.

The most recent gig is a tombstone for an upcoming film. Styrofoam is the obvious choice for this project.  I started with the vectors supplied by the Art Department. It was great that they sent everything to size! Our Techno ate through the job pretty quickly.
I used our little hot wire cutter to carve a couple of trenches on each side of the tombstone so I could glue in a piece of pvc pipe The pipe is there to accept the 2 rods that they'll pound into the ground on location. No worries if it's windy!
I used low expansion window and door foam as the glue. With a bit of water, it should be kicked in about 40 minutes.
After the glue had kicked, Jody got started mixing and applying our scenic mud. We tinted it grey to help out with the final limestone color we'll be applying tomorrow.
The base for the stone also got it's texture coat as well. We used the crinkled tin foil as a mold of sorts for the edge texture.
Once the mud had hardened up a bit, I rolled it with a heavy textured roller. Once that set up further, I was able to use the trowel to burnish the texture down a bit.
Tomorrow I'll get the text cut, and the final paint done!
Ahhhhhh...............Sweet, sweet Tombstone Tuesday.........