Manual Mill to CNC Conversion
A project involving the design and integration of stepper motors, drivers, and control software to convert a manual milling machine into a capable 3-axis CNC
My goal for this project was a two-pronged exploration into enhancing benchtop milling machines. The first part focused on creating the ultimate manual mill, outfitting it with a custom-built drive conversion for smoother operation, digital read-out (DRO) scales and a display for precision measurement, and an ingeniously designed X-axis power feed built from a repurposed car window regulator motor. The second, more ambitious part, involved converting an identical mill into a full 3-axis CNC machine.
This conversion showcases a comprehensive application of my design, machining, and electronics skills. I designed the complete 3-axis kit in CAD before manually milling all custom structural parts from aluminum blocks. This hands-on fabrication extended to turning the hardened ball screws and machining all the couplings to spec from scratch on my lathe. I was also solely responsible for the electronics, performing all point-to-point soldering and wiring to integrate the Geckodrive digital stepper drivers with the 24V motors and control system.
The successful customization of my manual mill and lathe, alongside the ground-up CNC conversion, has provided me with a powerful suite of tools for rapid prototyping and building anything I can design. Continuing my skill development in precision machining, my latest ongoing project involves a recently acquired PocketNC 5-axis CNC, where I am currently teaching myself the intricacies of 5-axis CAM programming and operation.