MULTICAM

Distort tool - EnRoute 5

2012-03-03T17:51:00.000-08:00

For Dustin's name tag I decided on an old western theme. He owns and operates a theme park with a railroad theme. I types in the lettering, enlarging the 'D' and 'N'. But it didn't flow. I'd fix that in a hurry with the new distort tool in EnRoute 5.

I tackled the center letters first. I selected all three letters and then opened the distort tool. It is as simple as dragging the nodes downwards. The letter vectors don't move with the grid until you hit apply.

I liked the look of the center section but after adding a top and bottom bar to the mix I decided the end letters also needed to drop down on the outside corners.

I did the 'D' first, then the 'N' on the other side.

I created the rest of the vectors I needed to create the plaque in EnRoute using the drawing tools. The center sausage shaped vector would be used to distort the relief later.

I created a flat relief in the shape of the plaque, then created a raised border around the inside by modifying the relief.

A wood grain bitmap was applied to the inside portions of the plaque.

Then as a separate relief I created the letter border.

The stars were also created as separate reliefs. These would be floated into position and merged highest in a bit.

Now i was time to create a special effect by making the letter outline barrel up through the center. I selected the letter outline and that usage shaped vector I mentioned earlier. This vector would be used to modify the lettering outline to the shape I desired. The stars were also selected in this screen shot but I later decided to lave them flat.

I checked the front view to make sure everything was at the right height before merging highest all of the elements.

The bands above and below the lettering as next created as flat reliefs, aded to the existing background relief.

Last up was the lettering created as a beveled relief.

The file was now ready for tool pathing, But I had removed the boots from the collets for a thorough cleaning and forgot to calibrate then before starting to route. The result was some 3/8" tool marks in the top of the letters done during the rough pass. I decided it looked good. I would leave it and perhaps use this trick down the road. The border edge of the plaque also had roughing pass tool marks. I used my die grinder to take them off in an instant. I purposely left die grinder tool marks, making the edges look like they had been carved with an adz or chisel.

It should paint up pretty cool. I'll be posting more pics as that process proceeds. Stay tuned...

-dan

Pure Magic

2012-03-03T11:42:00.001-08:00

More than six years ago I clearly remember watching my shiny new MultiCam run down the table, stop at a precise location and then magically carve away at a piece of Precision Board to reveal the piece I had designed a few minutes previously at my desk. It was pure MAGIC.

The pieces I designed at first were very simple for I had so much to learn. As most quickly figure out EnRoute has a pretty steep learning curve - especially if you want to do more than use your router as a very expensive jig saw. And I wanted to do so much more!

Each day I would try to add one more trick to my tool set. I knew what I wanted to create, but getting the program to do it was difficult - especially at first. As I became familiar with the controls I found I could imagine almost anything and then methodically build shapes, add, take away or modify to get what I wanted. The only limits were my skill level and my imagination.

These days I am very comfortable with the workings of EnRoute. I find it best that the room I am working needs to be quiet - no radio playing or distractions. Things need to be done in a precise order - from start to finish. Sometimes unexpected things happen. Rather than frustrating me I take note for I will use that command down the road to do something new and different. Then I back up a step and try something different.

The name tags for the Sign Magic Workshops are a chance to get a little crazy, to try out many new things. The whole idea is to go down roads I haven't travelled before. Creating a bunch of original name tags tunes up my skills and familiarizes me with things I haven't used for a while. It is necessary practice before I sit down to teach another workshop. I would highly recommend this task to anyone who wants to really learn to use EnRoute to it's fullest.

One of the name tags I created this past week was especially fun. The plaque was for Kurt who will be traveling from Pennsylvania for the Sculpting Magic Workshop. I got so wrapped up in the job I forgot to grab screen shots so I have no step by step for this piece. I'll let you figure it out like I did. :)

When I sent the file to the MultiCam I simply had to go to the router room and watch for a while. I felt that same feeling of seeing pure MAGIC happen as with my first piece more than six years ago. It was fun!

I hope you have as much fun creating files and routing as I do!

-dan

A star is born

2012-03-03T11:16:00.000-08:00

Chris' name plaque had a lot less steps compared to some of the others. It was to be a simple domed oval with border and slightly raised textured center. I tweaked the font I chose as the 's' was higher than the other letters. O made the 'c' and the 'r' the same height. This balanced the extender of the 'h' and the dot of the 'i' nicely. An outline around the lettering completed the vectors. If I am using textures for the background (which I almost always do) I like to put a border around the lettering as it makes the words much more readable in my view.

To start I selected the outer oval, entered a value for the base of 0.4" and an angle of 14 degrees. This means the plaque will be 0.4" thick on the edge and the dome will start at 14 degrees as it rounds over. I knew from experience that for this size plaque and 1.5" thick Precision Board this would fit nicely.

Next I again selected the oval relief and the inside oval vector and modified the relief by raising the selected area 0.15" Then I imported a bitmap from my TEXTURE MAGIC collection called 'frantic stars' I selected the oval relief , the inside oval vector (to define where I wanted the texture) I also selected the lettering border. Because it was inside the other vector I selected it acted as a hole, meaning the texture would not go here. I added a value of 0.15" for the texture which meant it would bump up by that amount.

Then I selected the oval relief once more as well as the lettering border. I would modify the relief once more to raise this area 0.2" - just above the frantic star texture.

The last step was to create the prismatic lettering. I selected the oval relief and the letters. I would use the prismatic tool which I would use to modify the relief. I entered a value of 0.15 for the base (vertical portion of the letters and set the angle of the tops at 21degrees slope.

Just like that Chris' name plaque was ready to tool path and send off to the MultiCam.

Stay tuned for more soon...

-dan

No horsing around today

2012-03-02T23:46:00.001-08:00

Today was a busy one in the shop, both getting ready for the upcoming Sign Magic Workshop and also working on some projects. The Lark Rise sign got the bulk of the attention today with the final base oats and glazes being applied. The ladies did the bulk of the work and did a great job too!

In the shot below Sarah and Haley are just finishing the second coat of glaze on the post.

In the bottom shot the first coat of the colors are on with a couple more to go. The last step will be the 23K gold leaf on the lettering.

We are almost there now!

-dan

Good enough to eat!

2012-03-01T18:07:00.003-08:00

The last time I made name plaques one of them looked a little like a plate of spaghetti. I decided I would try and push the envelope a little - just to see how far we could take it.

The first thing was to create a plate. I used the dome tool to create a negative impression.

What would become the spaghetti was done as a flat relief. The meatballs were created using the dome tool. Nothing hard here.

Then I applied a bitmap from my TEXTURE MAGIC collection. It is called spaghetti of course. I had to play with it a bit to figure out the right value to look good.

I modified the spaghetti oval and the meatballs by selecting them and a vector oval and then using the dome tool to hump up a good sized pile of delicious.

I used one other bitmap - the old standby, SPLOTCHES, to give the meatballs some meaty texture.

The letter outline was created as a flat relief that was .75 inches tall. Then I used the same oval vector that I had used to hump up the spaghetti and meatballs (and the same value in the input box) to dome up the lettering outline.

Looking in the front view I had to nudge everything into place vertically. The lettering border needed to come way down while the spaghetti needed to go up a tich.

Then it was time to add the raised lettering. Because I had not yet merged everything together I modified the lettering outline relief by adding he lettering.

It is important to keep checking all the way through to make sure the program is doing what you had in mind.

I thought the lettering was looking a little plain. A very light pass with the splotches texture would fix that in a hurry!

Before we merged everything together it was time to look in the front view and nudge things up or down as necessary.

I had created a zero height relief that was a little over sized. It had a small step in the edge so the router but wouldn't be running up agains the full height block of Precision Board. I used this was the base to merge highest all the other pieces to.

The file was tool pathed with a 3/8 ball nose bit @ 50% overlap for the first pass and a 1/8" ball nose and an 80% overlap in the final. As quick as that we had a plate of spaghetti - complete with meatballs.

I hope Gary likes spaghetti 'cause it looks good enough to eat!

-dan

Playing with new toys

2012-03-01T08:34:00.001-08:00

With the next Sign magic Workshop now only a week away we are very busy creating the name plaques we give each attendee. For the first one I wanted to create the look of an old piece of news paper with Darrel's name on it. The font I used was called American typewriter.

To get an antique look I decided I would give a new tool in EnRoute 5 a try. The tool is called noise distortion. It is found in the transform group, under the subheading of distort. Since it is a new tool to me I had to noodle around a bit to figure out, first how it work, and secondly how to get what I wanted for this file. The preview function proved to be real handy!

Once I had the look I wanted I deleted the original letter vectors. This was looking old and well worn already - and with just the click of a button instead of having to hand draw the wiggly lines as I have always done.

I used the offset tool to create a border around the letters.

I drew up a rectangle with rounded corners, then used the noise distortion tool once more to create the decal edge of the news paper. Once again it was with the click of a button rather than hand drawing it. This distortion tool is cool!

I enlarged the rectangle to form a backer board for the name plaque.

Then I used the point edit tool to quickly grab a few of the nodes to drag them in and form some rips and cracks in the edges of the news paper. It only took a few seconds.

I snapped a screen shot of the vectors and then opened the file in EnRoute. I would use this outline to produce a quick bitmap that I would use to shape the newspaper. I used a big fuzzy brush with the opacity dropped down to about 50%. I didn't spend more than a minute or two on the task. As I drew I kept in mind that black does nothing, white will raise up areas and grays do in-between , depending on their relative value. Looking at my bitmap I see that the edges will raise up with a couple of folds while the middle will drop down.

Then it was time to start in on the reliefs. I used the dome tool initially to create my plaque base.

Then I grabbed my tool outline and used this vector as a mask to modify the original relief.

I then imported the bitmap I had created and applied it to the relief. In the screen capture below the name and outline is selected as well as the plate and newspaper outline. It shouldn't be selected so if you are repeating this exercise make sure you don't do as in the picture.

To add a bit of a hump in the middle of the newspaper I applied a second bitmap. By understanding how the various shapes of white, gray and black affect the relief we can purposely create any effect we want.

To make the newspaper look just a little older I used my faithful SPLOTCHES bitmap using a small value to add some wrinkles to the paper.

The completed paper relief looked like this.

Then it was back to the letter vectors to modify the relief by adding the letter outline first.

The last step was td add the slightly domed letters.

I'll tweak it slightly with the die grinder as we prepare for paint but it isn't going to take more than ten seconds for what I want.

This new distortion tool works pretty cool. It is but one of the many new features in EnRoute 5 that will save me a bunch of work!

-dan

Butterfly house concept

2012-02-28T20:42:00.004-08:00

This week has been largely all about our new house and other business matters. Not much got accomplished in the studio or shop so far.

The new house was very much in mind when we purchased our first MultiCam six years ago and also the new four axis model we just replaced it with. You can absolutely bet that it will play a large role in the creation of countless pieces. Today we were talking with a cabinet shop as to how we could incorporate many unique features into the cabinet, working hand in hand with their shop on various components.
Other features of the house will include wainscoting, chair rails, wall and ceiling trim, big decorative beams, railings, light switches and hundreds of other creative do-dads throughout. The software, router and modern substrates like the heavy weight Precision Board will allow us to do many things we previously only could dream of. These details are still a ways out from production on the CNC but with the final blue prints now being drawn it is time to think seriously about how we will do it.

So here is a teaser of the outside of the house as the final look is refined through the last stages...

Since my wife Janis loves butterflies we will be incorporating that as the theme throughout. I present the 'Butterfly House'.

This is undoubtably going to be a fun project that will incorporate every single trick and technique we can muster. I am looking forward to it with great delight!

-dan

Workshops! Workshops! Workshops!

2012-02-28T11:04:00.000-08:00

These days we are thinking a lot about our Sign Magic Workshops. The next one to be held here in our studio is now only a week away. In the shop preparations are in full gear! I'll be posting some step by steps of some of the name tags I am making for our attendees later today.

Plans are also underway to have a workshop in the Ukraine or perhaps Moscow sometime later this year. I received a copy of the Ukraine sign magazine this morning and noticed a full page ad for the workshop. Unfortunately I am only able to read a few words.

There is also some serious talk of a workshop on the east coast in the New Jersey/New York area later this year. No firm dates have yet been set for that one. But as things firm up I'll be posting details here.

-dan

Chasing the elusive butterfly

2012-02-26T00:10:00.000-08:00

As we begin planning our new house in earnest, one of our happy tasks is to choose the perfect theme. Like our commercial projects the theme will extend to the corner blocks of the doors and windows and throughout the trim of the building. On commercial projects this is part of the branding, while in our house it will be merely decor. But the decor will have meaning and significance.

Janis has loved butterflies as long as I've known her. This house is the perfect opportunity to celebrate that love. So, the first task is to narrow down the theme and style. It turns out there are endless ways one can draw a butterfly.

I'll bet there are just as many clever ways to incorporate this theme as there are ways to render them.

Stay tuned...

-dan

A few more details

2012-02-24T22:19:00.001-08:00

Today was another day at the Fox and Hounds. We tidied up a few more details. The contractor had painted the cooler door edges and surrounding trim from bright white to dark brown. It looked pretty good!

We hung the hostess sign in the entry. I had done a few modifications from the original design.

We also pulled down a bunch of the direction and rule signs through the pub and brightened up the raised lettering, making them more readable in the dim light of the pub.

I double checked some measurements for one last routing project for the inside of the pub. I'll be creating an overlay panel for the back door that will be similar to the one I did for the cooler door.

Stay tuned...

-dan

The color starts

2012-02-23T19:36:00.000-08:00

With the carving and sculpting now done it is time to kick off the painting process. First the usual coat of FSC 88-WB primer from Coastal Enterprises. This smoothes things out a little and also is used to apply a subtle texture to the lettering by using a small brush on those areas. We set up a shop fan for a few hours to suck out the moisture. Then it was time to apply the first coat of acrylic paint. The post got an even coat of light brown acrylic house paint. It will be allowed to dry overnight and then it will get a second coat.

The sign was the second area to get some color. I started with a medium metallic grey for a base color. the sign background will darken up to almost black before we are done, but some cool highlights will shine through to give the sign sone sparkle. The 23K gold and bits of color will give this sign a lot of class. The same dark grey with black glazes will adorn the 'sandblasted' areas of the sign post but they won't be applied until after the glazes on the rest of the post are done.

Stay tuned for more progress...

-dan

Reaching around the world!

2012-02-23T13:19:00.001-08:00

It never ceases to amaze me that people from literally around the world take the time to follow our blog regularly. Most who follow the blog are fellow professionals, who desire to learn about how we do things in our shop. I get lots of emails from these folks which often include pictures of projects they have done, inspired by what they have seen on our website. It is kind of cool to know that we have provided some inspiration to people so far away, to people I have never met. The internet is an amazing thing!

Today I recieved an email from Konstantin, who owns Domino Art in Dnipropetrovs’ka oblast’ which is a province in the Ukraine. His email was short with the words 'Due to your ideas...' The email also contained some wonderful pictures of some very imaginative work. His email suggesting we helped inspire the work was gratifying.

Thanks for taking the time to contact me Konstantine! And keep up the wonderful work! Their website is at www.domino-art.com.ua

-dan

Sign Magic Workshop almost here!

2012-02-22T22:54:00.000-08:00

The last couple days have been frantic with many meetings and lots of organizing. I haven't had much time to create routing files. The beauty of having a MultiCam is I can easily keep it busy while I do other things. It can work all by itself(as long as I fed it the right instructions)

The next Sign Magic Workshop is just over two weeks away. So the CNC is kept busy cranking out textured letter panels for our guests to practice their painting and glazing techniques. Custom name tags for each guest will be the next task. I'll be doing step by steps on a few of those files in the next days.

Stay tuned...

-dan

Ultimate project?

2012-02-20T22:13:00.001-08:00

They say the hardest project for any artist to do is one for themselves. I know it to be true through experience. But these projects also allow us the ultimate freedom to do what pleases us and have the potential to be out best work.

My wife and I have been dreaming of our dream house for almost twenty years. We've drawn plan after plan, we've considered thousands of ideas. As you can imagine we don't want our house to be 'normal' in any way. From the first day I spun up the MultiCam more than six years ago I knew it would play a huge role in the construction. We've played and experimented with materials and finishes. Now the time has come to put all that experience to the ultimate challenge... our new house.

As the time draws near to begin construction the pace has quickened. It is time to put the best of the best of the ideas down, figure out ways to make it all work together. The final plan has to be functional, build-able within a budget we can handle and at the same time has to be the most incredible showcase for our work.

The ideas I'm currently drawing are not final, some are little more than rough scribbles. All are subject to change and revision. Some will hit the cutting room floor. But they are getting close and finally are boiling down to what we like. This will be a routing extravaganza both inside and out! before we are done we will also use every technique and trick I can think of.

Stay tuned for the best project yet!

-dan

Assembly

2012-02-19T23:57:00.001-08:00

Once the router was finished cranking out all the pieces of the Lark Rise project it was time to start in on assembly. The first task was to weld up a steel frame that would go through the sign and also down the post to provide structural strength.

Although the sign board looks like it can swing it is actually welded in place. The horizontal steel pipe is welded to the vertical pipe that goes from top to bottom through the middle of the post.

I used my die grinder to carve in the woodgrain into the post. The vertical cracks and splits were done with a narrow bit in the same machine.

I have a little more work to do on the back before we begin the priming and paint but it is almost ready to go already.

Stay tuned for more...

-dan

Routing times with textures

2012-02-17T21:54:00.000-08:00

A question that often pops up in our email box and at workshops is about routing times. Folks want to know how long it will take to run these kinds of files. The reality is there is no simple answer. Mostly it depends on the router you own.

My new MultiCam is significantly faster than my old router. I've been told this is because of more powerful servo motors and larger spur gears on the drives. I just know it is faster and quieter than my old one by far.

There is also the matter of how the router is set up or tuned for lack of a better word. When a router goes from horizontal travel to vertical travel it literally stops as it changes direction. This effect can be dampened somewhat by changing the driver parameters to have the router cut the corner a teeny bit, meaning it can be taken faster. My MultiCam tech tuned my last router for me and in the process sped it up by half before the quality of the cuts changed enough to notice. I'd love to have him come back and play with my current machine and in the process make the cuts a little smoother and have the machine speed up significantly. I can only imagine the speed we would get out of it then.

Servo motors can be pushed a lot harder than the old stepper motors, meaning these types of machines will cut down on the router times by a whole bunch. But all this costs money too and we have to decide where the wallet stops and the patience kicks in.

The files that take the longest are the ones with the most texture... with the detailed woodgrain files taking the longest. But they do look mighty fine when they are done. I come from the days when we did things the old way... applying the heavy sandblasting mask, pounding it down, then drawing out the design and patiently hand cutting the frisket, peeling out the parts not needed and then sandblasting the sign. That job is right up there with cleaning an oven (the old fashioned way). I can think of a thousand things I'd rather do.

Now I build the file in my studio, looking up occasionally at the gorgeous views I enjoy. Then I lay down a sheet of Precision Board. start the router and go do something fun.

Today I did a file that was a good one to analyze. It was a detailed sandblasted woodgrain that would push the capabilities to the max. It also has some flat bits so we could see how much the router sped up on those areas. The sign measured 44" tall by 28" wide meaning it was about 8.5 square feet in area. The file was programmed at 300 inches per minute horizontally (X and Y axis) and 150 inches per minute in the Z axis. It had an 80% overlap on the final pass using a 1/8" ball nose bit. The rough pass was done using a 3/8" ball nose bit and an 50% overlap and a 0.10" offset. I timed both cuts and also shot some stills and video.

Here's a shot of the rough pass in progress. The sole purpose of this pass is to remove material. In doing so it eases strain on the 1/8" tapered ball nose bit I use for the final pass. The roughing pass took 35 minutes from start to finish.

The automatic tool changer changed bits while I was answering my email this morning. I can fairly hear it from my office. The noise pitch of the small bit is slightly higher. This finish file took just under six and a half hours to route from start to finish or 45 minutes per square foot. Not bad in my book, and certainly a whole lot after than doing it by hand!

Here's the video of the finish pass. I programmed this file at 300 per minute but in the one minute of the video the router only travels 108 inches - one third of the speed I actually programmed it. The reason is the texture, slowing down the forward speed with the up and down movement. If you watch the movie all the way through you will notice the router speed up significantly on the bottom triangle and on the top part of the sign - both smooth areas. Obviously routing times will increase as detail is increased.

With texture being so important to the work we do in our shop I have to calculate these increased routing times into the project budget.

The thing to remember however is not to solely determine the cost of the project by routing times. If you do you are selling yourself short - especially if you have a fast router. If my hourly rate is the same as someone else's with a slower router and I price by time and materials alone, then the sign becomes cheaper - simply because I can do it faster. Personally I'd like to be rewarded for investing in a faster machine and stick the extra cash in my pocket!

-dan

Creating the Lark Rise sign files

2012-02-16T20:08:00.000-08:00

The Lark Rise sign was next up on the agenda. I created the lettering vectors in Illustrator and then imported them to EnRoute where I created the rest of the vectors for the design.

The sign face was fairly simple, with the inside to be routed out. The flags along the top were raised and bevelled.

I put some wood grain in the background using a sandblasted redwood bitmap from my TEXTURE MAGIC collection.

The lettering outline was built as a separate flat relief, moved into position vertically and then merged highest with the background.

The lettering was prismatic lettering created with the bevel tool and a 0.15 base. The triangle on the bottom of the sign was also rested with the bevel tool as a separate relief before being merged highest with the background.

The sign will be cut in three layers, the top face being routed from 1.5" thick 30 lb Precison Board. The middle and back layers will be cut from 1" 30lb Precision Board. I will weld up a steel frame to glue into the center to provide strength. Since I'm using 1"x1" square tubing I created 1.1" cuts through the center piece to make room for the steel. The glue will fill in any gaps.

The two cutting files for the middle and back looked like this when I was done. These will be shaped using an offset cut.

Stay tuned as the sign comes together...

-dan

Pure magic in four axis

2012-02-15T22:28:00.000-08:00

I love curves, textures and fancy bits, especially if they take a good design over the top. The fourth axis opens up a whole world f possibilities that weren't easy previously. It is pretty exciting.

In the last post I showed how we built a file of the twisted and fluted post with a beautiful taper. Now it was time to let the machine do the work. As I build more files and experiment with the tool pathing I am slowly getting more familiar and comfortable with it. I learn best by repetition and experimentation - both of which take time.

Here's a short movie of the process...

Stay tuned for more...

-dan

A weird shaped block

2012-02-14T23:07:00.000-08:00

This whole fourth axis routing thing is forcing me to think in brand new ways. Being all new means I really have to work at getting it right. I'm sure that over time it will become familiar and quicker. Knowing EnRoute means I don't have to learn much as far as the program itself. But this was using EnRoute in a whole new way.

The first thing I had to determine was how I would glue up the blocks with the maximum usage of my material.

I decided to cut the blocks to shape in the top view as well. While it wouldn't save much materials it would save a bunch of sawdust on the floor as I routed and perhaps a little wear and tear on the machine. I would cut a rounded center slot in the two center pieces to accommodate the steel pipe I would glue in there and use as a centerpiece to clamp to. This steel would also provide structure to the sign post. The center slot was created as an inset relief. The balance of the routing would be simple offset cuts. The MultiCam made quick work of this project. Each piece would be cut twice.

Once the MultiCam was done it was time to start gluing up the 30 lb Precision Board. I used Coastal Enterprises PB240 - a one part glue activated by a spritz of water. It expands as it cures so lots of secure clamps are necessary.

We are almost ready to kick the lathe into gear. Stay tuned...

-dan

Details, details and more details

2012-02-13T19:36:00.000-08:00

We are down to the final bits and pieces for the pub project. As they begin to operate for real in the renovated facility the need for an abundance of operational signs immediately became apparent. For these signs we opted for a faux copper look. The signs do what they are supposed to but blend into the scenery.

The files are simple but effective - still dimensional but not overly so. The signs are simple flat reliefs with a subtle texture (from the TEXTURE MAGIC collection)

The washroom sign reliefs were all built separately and then merged (highest) as a separate step. The front and back of the sign were build in separate pieces and glued tougher after routing. The eye bolts were welded to a steel rod which was laminated into the center for strength.

The lettering was added as a last step as a slightly domed relief.

The pieces were routed from 1" thick 30 lb Precision Board. The signs were roughed out with a 3/8" ball nose bit and the find pass on the MultiCam was done with a 1/8" ball nose bit.

I sculpted the hand using Abracadabra Sculpting epoxy. It was all painted with metallic acrylic paints, then aged with dome dark brown glaze.

There were lots more of these small signs throughout the facility and the list seems to be getting longer all the time.

We also hung the Keep Calm sign today. It looks at home in its final place.

-dan

Creating a file for a fancy turned column

2012-02-12T22:48:00.000-08:00

The center section of the post is the next assignment. It will be routed on the four axis MultiCam. First I had to determine the scale and shape of the piece. I called up the tracing I had done of my concept drawing. I duplicated the center section flipped it and lined it up before merging it with the first half. I then measured the diameter, length and also did a trace of the profile. These measurements and the vector would be used later.

I wanted the post to look like it was turned with flutes winding around. to create these I drew a long rectangle and then used the duplicate menu to create a 12 copies.

I created a rectangle that was 36" tall by Radius times Pi. I positioned the pieces, rotated the flute vectors so the joining sides would line up. I created two horizontal vectors to line up with the ends, and also lined up the profile.

I selected everything and rotated it so I would create the relief in the horizontal position. First I would create a mesh file of the profile using the sweep two rails function. It is a simple process. I selected the mesh command., then defined the slices and stacks. I tend to use higher numbers than necessary but my computer can handle the large files. The command prompts make it easy. Select first rail, then the second.

Then it asks for the swap sections. Clicking twice on the profile will define the shape all the way across with the same profile.

The mesh looks like this when it's done.

I then created a zero height relief (in yellow). When I hit the render button it only showed part of it. This immediately told me the mesh profile was too low.

I checked the front view and sure enough the mesh file needed to be raised.

The next operation was to merge the mesh with the relief, I selected both the mesh and the relief which lit the combine button. I used the ad to button and hit apply.

In an instant we had a relief in the shape of the profile of the post.

Next up we would create the rib reliefs. I selected the vectors and then used the dome command.

It looked like this when it was done.

I merged the profile relief (as the base relief) with the dome ribs using the add to command.

Once I was done I rendered it to check and see what had happened. It looked perfect.

In the 3/4 view I could really see what was happening.

I used the sweep two rails function to create the bottom of the column. as a quarter round. I moved it up into

I did the same for the top of the column.

As easy as that the relief was ready to wrap for the four axis router.

The simulation of the wrapped relief looks like this...

I have to check everything over and confirm all measurements, then I'll tool path the file and get it ready to send off to the router. Before I can do that I have to route the blocks to shape that I will be glued up for the block. It will have structural steel laminated through the center. I'll be showing that process next. Stay tuned...

-dan

Pressing on in spite of temporary doubts

2012-02-10T12:03:00.000-08:00

In spite of a whole bunch of other necessary work going on in the shop I could't resist sneaking another half hour with the die grinder on the piece. I whipped on the wood grain, and as I progressed I was more than a little unsure that I may just have wrecked the piece. But I trusted my instincts and pressed on. Then I changed bits to a fine pointed one and started in on the splits in the 'wood' It instantly looked great - just as I had imagined.

You have to look at this piece in context of the rest of the post and sign. I want the woodgrain and weathering to read clearly at a distance. People will be looking at this sign as they drive by in a car. As we layer on the paint and subtle glazes it will hopefully be magic.

Now I m ready to fill in the holes and add a few details with the Abracadabra Sculpting epoxy. It's time to kick the router into gear on the next pieces.

-dan

Horsing around with the die grinder

2012-02-10T09:44:00.000-08:00

About 50 minutes with the die grinder got rid of all the seams, and allowed enough time to rough out the final shape. I also flattened out the bottom of the head on the giant disc sander and glued it onto the base plate. I'll study it a bit before I carve in the woodgrain and add a little more detail with some sculpting epoxy. We have to remember this is just the post topper. There is no sense in getting carried away and spending too much time going crazy with detail that would only be lost in the overall picture.

Stay tuned as I'll be back with a few more pics later today. This thing is so fun I'm having trouble setting it down. But there is other work to be done today too. :)

-dan

Pure fun - without breaking into a sweat

2012-02-09T21:19:00.000-08:00

Today we did the last of the routed interior signs for the Fox & Hounds Pub. They were glued in readiness for the finishing in the next few days.

Once they were off the router it was time to kick the Lark Rise sign into gear. The horse's head was the first task. It was routed in four layers of 1.5" thick 30lb Precision Board. I then glued it up in readiness for some quick hand carving. If we were doing multiples it would have made sense to spend more time on the modeling and add more fine detail. But I would rather spend my time doing this work by hand - after allowing the machine to do the hard work - roughing things out. The horse's head is about 16" tall and 6" thick as a point of reference. Once I have flattened the bottom of the neck it will be fastened to the round base below.

Stay tuned...

-dan

It's all about reliefs

2012-02-08T22:51:00.000-08:00

I started in on the Lark Rise post today. This is both challenging and FUN! To do a project like this you REALLY have to understand how to make reliefs, and what happens with the merge commands. There is no faking this kind of complex file.

I first created vectors by hand tracing the various elements of the post. Some of these vectors would only be guidelines for the finished files. Others would need to be tweaked to make them work. The post will be created in sections that will fit together over a welded steel frame. Today's file would be the horse's head.

The flower decoration on the post was simple. I'll build this file tomorrow.

The horse head vectors were built separately. I had to think of what shape I would create as I formed the reliefs. I tested each relief shape as I went, and then adjusted the vectors until I was happy with the result.

I worked the vectors for the post all the way down. The middle section will be created as a relief that will wrap and create a 4 axis file that will be routed on the rotary MultiCam.

EnRoute is an amazing program once you get a handle on the functions and understand what is possible. Each element was done individually with the exception of the eye and neck bulge which were added to reliefs.

These relief were combined by merging highest, merging lowest and merging by replacing with another relief. I clipped the bottom flat with another zero hight relief then used the slice command to take away the portion I didn't need. The end result is the stylized horse head I was seeking. It will take a little hand work to finish but not much.

I then created two 1.5" tall slices to fit into the same thickness Precision Board, copied them and positioned them for routing. As quick as that the first section of the fancy post was ready to send to the MultiCam.

Stay tuned for more...

-dan

A few more things off the list

2012-02-08T17:21:00.000-08:00

This morning I loaded the front seat, back seat and box of the truck with completed signs, materials and tools I would need and then headed to the Fox & Hounds Pub. The dart board was the first piece, then the cooler (CELLAR) door. Above it I finished sculpting the fittings and taps onto the purposely exposed telephone conduits. When I added the rich copper paint and then the aging it instantly became one more magical area that makes this place so special.

I replaced the temporary signs with the faux copper ones we had fashioned.

I also added the 'licensed' plaque to both sides of the restaurant sign.

These many small details add so much to the overall feel of the pub. It is looking better each day and at the same time my to-do list gets ever smaller.

-dan

Score another for me

2012-02-07T17:28:00.000-08:00

Today's project didn't happen on the router table, nor on a computer. It was all hand done with the help of a plasma cutter and my trusty grinder. The project wasn't complex nor did it take long. But it's one more small piece in a complex puzzle that is the Fox & Hounds Pub. The details matter a great deal, and we are down to the details. With all the work we put into the dart board surround the score board simply could't be ordinary. My client had suggested some carbonized darts stuck into the top of the dart board but after a little research I discovered the center of the bull's eye needed to be 5' 8" off the floor. With the dropped ceiling in the stage area the darts would have even lost or even squished visually where the dart board was to hang. We had decided on a rusted steel chalk board(painted with some blackboard paint) Instead of welding three darts to the board I decided instead on one dart, abandoned after puncturing through the steel blackboard but bent and rather stuck in place. It struck me as funny as - well the 'deadly serious' game of darts.

Since the blackboard brush has a habit of getting lost I came up with sure cure. A sturdy chain is welded to the bottom of the board. The other end will be securely bolted to the blackboard brush. It will stay put for a long time. :)

Now it in on to some more details...

-dan

A little of everything

2012-02-06T22:56:00.000-08:00

One of our current projects is one that will use pretty much every feature and technique we can muster including the four axis capabilities of the MultiCam. Textures, bevels, layers, fancy turning, indexing, and plenty of bits and pieces and lots more are used on the sign. Our client owns a small acreage, with buildings that evoke a Hobbit feel. They also liked old English pubs. They had named their property Lark Rise Horse House. Obviously a horse theme was needed. My first sketches nailed the basic concept.

My first presentation was based on these sketches. But once I got to see the property some small changes were in order.

The second version included the house number on the post.

The client reviewed the design and asked for a few small final revisions. I changed the banner shape and decoration and darkened the sign backgrounds as per their requests.

The sign background Was built up from a number of shapes.

I used the basic sign shape, combined with other shapes to build the sign. Using the offset line command was used to create the borders.

The lettering was next on the agenda. I decided to build it independently of the sign. I hand traced the concept sketch I had done, purposely leaving it rough. I knew from experience that this would create wonderful , aged letters when I used a bevelled relief. The letters will be gilded on the final sign. The various facets of the bevelled lettering make the gold really shine.

The lettering border was first. This was created as a simple offset. The relief was flat.

Then I selected both vectors and then modified the letter border with the bevelled lettering.

'Horse House' and the bottom triangle were created in a similar fashion. Next time I'll be working on the background. The sign will be routed in three layers so it can easily be glued up around the welded steel frame.

After that I'll start in on the fancy turned post - all to be done on our MultiCam. There's lots of bits and pieces to this project. Stay tuned...

-dan

Go ahead - throw things.

2012-02-05T20:50:00.000-08:00

It's not often we would encourage anybody to throw sharp things at something we have labored over but as always there are exceptions. today's project was just such a case. I put the finishing touches to the dart board Frame for the Fox & Hounds Pub. With the rich reds and the deep green felt it looks pretty cool. Installed in the pub it will look even better.

I wonder how long it will be before the first dart hits the frame...

-dan

Two more pics

2012-02-03T21:40:00.000-08:00

Today we had company and went for lunch at the Fox & hounds Pub. I was delighted to see the place buzzing. I sat facing the door and watched people as they came in. It was obvious who was new or hadn't been there since the renovation. As they entered they would smile and I could see the delight in their faces. As they enjoyed their dinner they were rubber necking and pointing out various signs and features as they took notice. The place felt warm and inviting - just as it had been designed to do.

Since the last time I had gone a light had been installed over the Rover's Return sign making photo possible at last. It looked good there.

On my return to the shop we put the finishing touches to the Shady Rest sign. It is now ready to go to it's new home.

Now it is time to get busy with the many other projects on the go in the shop...

-dan

EnRoute 5 - MOST exciting feature so far.

2012-02-03T10:29:00.000-08:00

Yesterday I posted about my first impressions of version 5 of EnRoute. I had discovered the warp/distort feature but didn't have much time to play as of yet. But you can bet my mind was racing with all the new possibilities and added power this gave me to design.

In creating the last job we did I had spent the most time creating the waving British flag at the top. Getting everything tweaked perfectly took me quite a while. Each section had to be done separately.

With the new distort feature in EnRoute 5 this promised to be a whole lot easier. So I opened a flag vector I already had and gave it a whirl. The flag vector I had was a trace from a bitmap. Not especially accurate but it would do.

I selected the vector I wanted to trace and then clicked on the distort menu. It is found under transform. EnRoute instantly overlays a grid on my vector.

Then I go over the drawing grabbing the various nodes and pulling them to the shape I desired.

WHen I was happy I hit enter and PRESTO! What had taken me a great deal of time only the day before yesterday was now possible in seconds. How cool is that!

I am really liking version 5 of EnRoute already! Thanks to the folks who worked so hard and long to make it possible!

I talked with EJ, EnRoute Product Director, yesterday and he says it is on the way very soon!

-dan

Darts anyone? Part two

2012-02-03T10:17:00.001-08:00

The circle frame was domed slightly upwards. with a raised rim, inside and out.

I would put two textures in the donut, The first is one I call klingon chicken. It is a great random pattern.When I applied the bitmap I also selected the raised lettering to exclude it from these areas.

The second bitmap texture was one I use a lot called splotches. This randomized things just a little more. I also applied this texture to the British flag that is on the top.

I had built the British flag as a separate relief which I now merged highest with the base relief.

The relief was not ready to be tool pathed and sent to the MultiCam.

The file was ran with a 3/8" bit at a 50% overlap as a rough pass and a 1/8" ball nose bit with an 80% overlap for the final pass. As you can see in the photo below I tucked the crown into the corner to use up the small bit of wasted material there.

Tomorrow I'll be gluing it all together and gestating in on the painting process.

-dan

Laying on the paint

2012-02-02T20:56:00.000-08:00

Today was spent largely laying primer and base coats on a whole lot of small routed pieces in the shop. This stage of our projects is the least spectacular but time consuming none-the-less. The small shady rest sign got the most color with the foliage receiving one glaze with more to come. This sign will come together quickly as I work my way down.

Tomorrow we'll show a lot more progress as it comes together.

-dan

Kicking the tires on EnRoute 5

2012-02-02T10:08:00.000-08:00

EnRoute 5 has been eagerly anticipated for some time. Now it is only weeks away.

Recently, I was asked if I wanted to test drive a pre-release version of the software. I jumped at the opportunity! I loaded it up on my computer and proceeded to give it a whirl. I had heard rumors of some great new features, but like all users of the program my first concern was how would it handle the things I already do with the software every day.

I was going to work as I always had first and then I would quickly see how things were different. I'll go exploring and learning the new things a bit later.

The interface looks very similar. The logo and icons are green instead of the familiar blue.There are a few new buttons of course but everything I use is still in it's familiar location. Being a man of moderation I of course loaded it with a massive mesh - something EnRoute 4 had choked on. I was pleasantly surprised to see the rendering was faster than ever and EnRoute 5 handled the task with relative ease. Good news for the things I do. In fact, everything seemed a little faster - even on my two year old iMac, running Windows through Parallels.

I had heard from Jeff Hartman, one of the writers of the program that a new feature was going to be included that would allow us to distort vector lines automatically. This was a feature I was looking forward to. I found it this morning. It is a button called DISTORT in the transform menu. There are three sub menus. Patch Distort, Taper Distort and Noise Distortion. I was noodling around trying all kinds of things and found something VERY EXCITING.

I knew it would alter vectors and that is a powerful tool. I know I can use this effectively in our work in the future. But as I played around I discovered the Patch Distortion tool also modifies completed reliefs.

Below I have a screen capture of my experimentation. The top rectangular vector was modified with the noise distort function. I ramped it up to the extreme to dramatically show the effect but it can be precisely controlled by entering values into the box.

The same rectangle was modified in the second example using the Patch Distort function. Gentle sweeping curves and distortions are instantly possible. This is a cool feature!

The third example caught me by surprise. On a whim I opened a completed relief I was building this morning. I tried the Patch Distort function on it and it worked fabulously! I could distort both within the relief as well as the outside contours. This is COOL and will allow me to modify and tweak my designs after they are done. IMAGINE what it possible now!

There are many other new features in EnRoute 5. I have yet to test drive or even discover all these new things. One thing I have heard some buzz about is the ability to now nest on partial and irregular shaped sheets of material. That should be real handy. I look forward to our Spring Sign Magic Workshop where Jeff will show us everything in person. It is going to be fun!

After only a couple of weeks of use I already know I'll never open version 4 again. Version 4 was a huge improvement over version 3 and it looks like the folks at EnRoute have done it again. I already like this new version so much better! I can hardly wait to do a little more experimenting!

-dan

Game of darts part one, anyone?

2012-01-30T21:44:00.000-08:00

We are still working on details at the Fox & Hounds Pub. The to-do list is slowly being whittled down to size. Today I designed and routed a whole load of small signs, NO SMOKING, MECHANICAL ROOM and such. They'll be given the faux copper treatment, so they are there, but don't detract from 'the look' we have worked so hard to achieve.

I also built a couple of complex files and sent them off to the MultiCam. I'll be posting one today and one tomorrow, even though they were combined into one routing file.

The first was a small sign that used some pretty useful EnRoute techniques. It is more complex than anything I would have tackled when I was starting, but broken down into small steps it is manageable. So let's begin with a crown. I first roughed out basic half crown vectors, not worrying about shape or size. We'd tweak things up later.

Then using the vector editing tool I adjusted the nodes and added the curves to the vectors. Once I was happy I duplicated the vector shape, flipped one of the pieces and lined things up before merging.

Then I created the lower and middle rings for the crown starting with simple rectangles and then tweaking them using the vector modification tool. The basis crown relief was created as a zero height relief. The two ribs were dome reliefs with a 0.15" tall vertical edge. I added the wiener shaped oval around the combined reliefs. This would be used to modify the relief.

The result was a crown that bowed outwards real nice!

Then it was on to the flag background for the sign. First up was the vectors - all done in EnRoute. Other than the overall size of the sign everything was eyeballed, using EnRoute's tools to rotate, center and space things so they looked right. I would resize and slightly distort the lettering as needed later.

The jigsaw tool was the tool of choice for much of the next operation. I worked my way around the flag creating new vectors from the inside profiles of the combined shapes.

The center cross had to wait until last when all but one of the original vectors was gone. Now we are ready to begin the final work at last.

The crown was moved into position and an outline added. Then the lettering was positioned, resized and stretched a little before adding the outline. Now we could begin building the flag background relief.

A .045 "flat relief was first, then this flat relief was modified with the flag vectors, raising them by 0.15".

I then imported the splotches bitmap from my TEXTURE MAGIC collection. This would add a subtle wavy texture to the colored flag sections of the Union Jack.

I then created separate flat reliefs of the outlines of the lettering and crown. These were raised to clear the flag and textures, then merged highest to create one file.

The last step was to ass the bevelled prismatic lettering.

The file was then ready to tool path and send off to the MultiCam.

Stay tuned for the second half of this project...

-dan

Day of rest

2012-01-29T19:26:00.000-08:00

Today, I finished the sculpting on the Shady Rest sign. It was fun to add all the small details such as his wiggly toes, his big belly and the had pulled down low over his eyes. This guy is out for the count. A bunny sneaks up below - not worried by the fellow sleeping overhead.

The sculpted tree foliage was a first for me and I was pleased with the result.

Now it is on to paint. Stay tuned...

-dan

Time to fly!

2012-01-28T15:45:00.000-08:00

Today, being Saturday was sort of a day off. Janis was busy with horse stuff and so I had the time to do what I wanted in the shop. It has to be fun! And what could be more fun than doing the last of the painting on the balloon and then hanging it in it's permanent home in the studio.

I dragged my tallest step ladder in from outside then drilled some holes in the vaulted ceiling and securely fastened in the strong aircraft cables I had bought for the occasion. Then it was time to 'fly' the balloon into position. This balloon was definitely heavier than air! It didn't take long to secure everything perfectly. A few touchups made it all ready for the photo shoot.

The first four axis routing project is now officially done!

-dan

Working in the dark

2012-01-27T20:41:00.000-08:00

Yesterday, in the early afternoon, when I went up the road to get some small supplies from the local hardware store we noticed some smoke coming from a neighboring building. The fire department was called but before they even arrived the fire was well out of control. The flames were so high they engulfed the power and telephone lines putting all of Yarrow out of commission for the day. Power was restored before long but the internet was out into the night.

This morning things were back to normal but around nine thirty it went black once more. A fire at a local electrical substation knocked power out for thirty thousand homes and businesses in the area. Thankfully I didn't lose any computer work nor did I have the router running but we did already have a good amount of epoxy mixed so we pressed on with our work in the semi darkness of the shop.

Around noon we headed into the Fox & Hounds Pub to do the last of the touchup painting there. Tomorrow things will hopefully go smoother in the shop. Stay tuned...

-dan

Built to last

2012-01-26T08:47:00.000-08:00

Then it was time to take the routered pieces of Precision Board off the MultiCam and make them into a sign.

I used the center pieces of the sign as a jig to hold things nice and steady I cut short lengths of 1" x 1" steel tubing to length, approximating the angles by eye. The beauty of welding is that small gaps are easily remedied with a MIG welder.

The welding only took a few minutes. It created an extremely strong frame that will be laminated inside the 30 lb Precision Board sign.

A few seconds of grinding on each side flattened the welds to make the welded metal pieces fit nice and flush into the sign.

I also bent up an welded some 5/8" solid steel rods on each side. these would form the armature for the trees. I cut a small slot in each side of the sign with my air powered die grinder to make room for them.

Then I used Coastal Enterprises PB BOND-240 one part glue to hold everything together. I clamped things up tight as the glue expands as it cures. I left it clamped overnight.

The net morning it was time for a little more welding. I used up a bunch of short pieces of 1.5" x 1.5" square tubing which I save for this kind of job. THe triangle tubing which sticks out of the bottom of the sign was leveled up and welded into the top of the new steel. I then used some 1/4" steel pencil rod to form the hammock, tree branches and also to create a framework for the thicker bottom of the support branch. the Abracadabra Sculpt will be formed around these sturdy supports.

Now we are on to the sculpting phase of the project. My two helpers are in the next couple of days and it should go pretty quick. Stay tuned...

-dan

A change is as good as a rest.

2012-01-25T21:04:00.000-08:00

We don't do a lot of residential and cabin signs but when we do I enjoy them. In this case the owner's wanted something playful that reflected their relaxed time at their cottage. After some discussion we decided a fellow asleep in his hammock was the perfect image. The trees leaning inward under the weight of the sleeping fellow was a humorous twist. The chicken was added as an afterthought. After the drawing was done he was changed to a bunny. I never bothered changing the drawing but the final sculpt will include a rabbit. This project would be a combination of routed 30 lb Precision Board, welded steel (to make it good and strong) and some Abracadabra Sculpt.

The entire project routing file was designed in EnRoute. The first step was the vectors. The font called 'Quickdraw' is one I made some time ago, available at Letterhead Fonts I bounced the letters around a bit to make it fun.

I added an outline around the letters and then duplicated the file. Only the outline was flipped to make it a double sided sign. The two sides of the sign were from 1.5" HDU. I made up one more copy of the outline to be routed as an extra layer to make the sign extra thick. This would be cut from 1" thick Precision Board.

I I then made up a triangle of 1.1" thick rectangles. This would be routed out to allow a welded steel frame to be embedded into the sign as a holder and reinforcement.

I positioned the merged triangle and then used the jigsaw tool to create new vectors which I would use as a cutting guide.

Then it was time to start in on building the relief. I built a flat relief and then added the raised lettering outline.

Then I modified the relief one more time by adding slightly domed letters.

On looking at the file I decided the holes or the steel were too close together to I went back a couple of steps and redid the triangle, making it larger. This allowed more of the triangle to hang out of the bottom of the sign..

Then I used the jigsaw tool once more to create the vectors I needed to make the outline I wanted, deleting the old ones.

The sign was now ready for tool pathing and ready to send to the MultiCam.

Next time I'll show how I welded up the frame and made the sun ready for sculpting and paint. Stay tuned...

-dan

Workshops coming fast!

2012-01-25T08:43:00.000-08:00

Our next Sign Magic Workshop is now less than eight weeks away - March 9-11, 2012. In these workshops we talk about, show and practice, hands-on, all the things I write about here in the blog. We cover many other subjects as well including marketing and selling of three dimensional signs. There are no secrets, nothing is held back as we do our best to cram 45 years of experience into three days of learning.

We have a few seats left for this workshop. If you wish more information you can go to our website

SIGN MAGIC WORKSHOPS

SCULPTURE MAGIC WORKSHOP

Or you can drop me an email dan@imaginationcorporation.com

The three day workshop is to be held in our studio/workshop

Sawatzky's Imagination Corporation

42392 Yarrow Central Road

Yarrow (Chilliwack) British Columbia

Canada V2R 5E2

604 823 2216

Town crier sign(s) done.

2012-01-24T14:33:00.000-08:00

Yesterday I worked on the signs adding color after color, glaze after glaze. Each stage went quickly and by the time I was done every square inch of the signs had at least four layers of paint/glaze - some up to six coats. Because of the design and routing of multiple layers and lots of textures the process went easy. For tricky areas like the lettering I just had to drag a brush over the raised parts making cutting of the edges a snap.

Now it will be up to the owners to chose their favorite and I'll hang the other in my studio as a sample piece. Having finished samples on hand makes it easy to sell more of this kind of work in the future.

If it was your choice which one would you pick?

I do have a favorite but I'm not telling...

-dan

Sign comes to life with color!

2012-01-23T12:45:00.000-08:00

The two signs are being worked on simultaneously with progress being about equal. Similar but not the same, I'll let the client choose the one they want and I'll hand the other in our showroom as a sample to encourage future sales of this kind of sign.

The paint started with Coastal Enterprises heavy bodied primer FSC-88 WB. As is my style I brushed in on with a small brush, purposely leaving brush stroked behind. This adds character and goes a long way to making the sign look hand made.

I used Modern Master's Acrylic Scenic paint for the base coats. It was also brushed on by hand. I worked with a very limited pallet, custom mixing my colors as I went. The gold paint is from Modern Masters Metallic line of paints.

I worked on the top portion of the sign initially as I like to splash paint around. Once the top part is done I'll start in on the bottom portion. Next up is the glazing process.

Stay tuned...

-dan

More than just a pretty face.

2012-01-21T19:08:00.000-08:00

Structure is critical in our work. Structure comes in many forms starting with the substrates we choose. In our shop I like to use 30 or 40 lb Precision board exclusively while most shops stick with the less expensive 15-20lb HDU. The numbers refer to the pounds per cubic foot. The higher the number the denser and tougher the product is. I want to sleep good at night and knowing I have used the best possible product for our projects means they will be a LOT sturdier and withstand a lot more abuse down the road.

The small sign we are building now is a good example of our sturdy construction methods. When it came time to build the town crier's arm I first welded up a sturdy armature from 5/8" steel rod. This was epoxied deep into the 30 lb Precision Board. I know that no matter what this guy's arm is going to remain intact.

Once the steel rods were epoxied into place I did the sculpting of the hand and arm, knowing it will stay in place no matter what.

There is also some steel mesh embedded into his hat giving it a lot more strength like steel inside a concrete deck. Overkill? Perhaps, but if it never fails then it has done it's job.

I'll be sleeping well at night knowing the signs I build won't fail due to poor material and shortcuts in their construction. Most of my customers and those who see it will never know. Hopefully they will be concentrating on the pretty face. :)

-dan

Ring that bell!

2012-01-21T14:55:00.000-08:00

Today's project was a simple one but it shows an EnRoute tool I use a lot these days. The tool is the revolve tool. Once I learned it I found it easy and handy too!

The job was a small bell (actually two) for the Town Crier Whiskey sign(s). Everything was done in EnRoute. I first used the drawing tools to create a profile of half the bell. Then I drew the centerline. The profile would be revolved around this point.

The tool in the men bar looks like a wineglass. Select this. Then I filled in the parameters I needed to create a mesh. (100 slices and 100stacks) I selected the profile (as prompted) before hitting the blue forward arrow. Then I selected the centerline.

When I fit the checkmark I got an instant bell shaped mesh.

I then created a zero height relief. Once I was happy with the shape, size and position I selected both the mesh and the relief. This lit up the combine mesh button and allowed me to do just that. I could then delete the mesh.

I forgot to get any more screen captures but I used the slice tool to get rid of the zero height plate, then duplicated the bell three times to give me my four halves (for two bells) I arranged them and positioned them to cut in one piece from 1.5" thick 30 lb Precision Board HDU. I used a 3/8" ball nose bit with an 80% overlap. I knew it would leave slight tool marks but I am going to be covering the bell with sculpting epoxy in any case so it was of no concern. With the tool paths done it was time to fire up the MultiCam...

As you can see it cut in a hurry! I had the dust hood up and I was blowing with an air hose to keep things clear of dust for the video. Next time I'll show how we fastened the various pieces of the sign together. Stay tuned...

-dan

Here and there and everywhere.

2012-01-20T20:00:00.000-08:00

Today was one of those days where I jumped all over the place. As the day progressed it seemed I got little done. Some days are like that. But through it all the MultiCam kept real busy carving out the Town Crier sign. The truth is it was even busier than that for I couldn't resist doing TWO of the delightful signs. I simply had to have one in my shop as a reminder of this job. I definitely want to do more of this kind of work in the future and the best way to ensure that is to have some samples hanging on the wall of my studio.

As soon as the MultiCam finished the first sign background I peeled it off the table and set to work. I fastened the head to the sign board and mixed up some Abracadabra sculpting epoxy. His hat was first, roughed out to get a sense of things. He need ears of course and these were added next. It was almost time to go in for supper but I decided his powdered wig better be added while the ears were still soft. There would be no adjusting them later.

Now it REALLY was time to go in for supper for it was my turn to do the cooking but I had a little sculpt left over - just enough for his tongue.I quickly added it and decided it looked cool. I was happy at last. But as I turned away I just had to go back one last time to add one last detail... a little texture on his tongue. It made it all believable and helped sell the story.

Tomorrow I'll be back to add some more without a doubt. Stay tuned...

-dan

Old and new blended seamlessly

2012-01-19T22:07:00.000-08:00

I love to blend old fashioned, hand crafted ways with the modern tools. Digital tablets, virtual sculpting with a modern computer program, file building with EnRoute, and the CNC router of course are blended with hand sculpting, carving and painting to create our art pieces. In the last two days I used a wide variety of tools. I sketched on paper with an old fashioned pen to come up with a concept. Then I used a digital pen and tablet with a computer to put together the final concept. The rough sculpt was done using a virtual digital sculpting program. The was imported into EnRoute to create a routing file I then sent to our MultiCam router.

Once the MultiCam had done its job it was time to break out the hand tools to add the finer features and detail. The sculpt will be done in stages but I made good progress in the first go.

The right tool for any job is the one that works best. Tomorrow I'll do some more.

Stay tuned...

-dan

Shout it out!

2012-01-19T11:37:00.000-08:00

We needed one more sign for a key area in the Fox and Hounds Pub. The sign wouldn't be large, measuring about 30 inches tall at most but it needed to shout out. We toyed with a multitude of ideas and I filled my sketchbook with ideas but nothing clicked. The owner of the pub had asked for a sign that featured whiskey and was very British. Yesterday I typed pub signs into google, looking for inspiration. I didn't see anything I liked but I did get an idea. Town criers dated back to the 1500's. I did a quick sketch and knew this was the perfect idea.

The idea I had scribbled needed a lot of work. Then I remembered a drawing I had done more than twenty years ago. It had been sitting on my bulletin board just waiting for it's day to shine.

I pulled it into PhotoShop and cut, pasted, morphed, stretched and tweaked until I had what I wanted. I then redrew the town crier adding a hand with a bell, a tricorne hat, a powdered wig and a ruffled shirt. It made me laugh while I covered my ears. This guy is obviously LOUD!

Then I added a scroll with town crier and panel underneath. A whiskey barrel head for a background finished the story and tied it into the Pub decor nicely. The colors will also mirror everything else we have done to date.

Then it was time to start in on the sign design. I created the basic vectors in Illustrator then Imported them to EnRoute.

I opened a barrel I had created for Big Ben the horse as it would save me building this part again. I changed it from an oval to a circle to fit this design.

Using the basic layout I created half of the banner using the drawing tools. I then copied and flipped it for the other half before merging them together. The guild lines were then deleted.

Then I built one end of the scroll, copied, pasted and flipped that for the other end. I stretched out the bottom panel and added a couple of buttons.

The lettering file I chose was good but a little thin for routing. The cure was easy. I simply added a thin outline and then deleted the original lettering making things a little bolder. I often do this with thin fonts.

I wanted the banner to bow up a little so I drew an oval around it and by selecting the banner relief and the oval I modified the banner relief using the dome command.

Then I added a texture to the whiskey panel using the 'splotches' bitmap from my TEXTURE MAGIC collection.

I added the prismatic lettering and then combined all the relief into one file, ready for routing.

For the face I created a rough sculpture in Mudbox - a freehand sculpting program. It exports an .obj mesh file. I converted this to a .stl file in another program and then imported this into EnRoute. I sized, rotated and positioned the mesh and then created a zero height relief to which I would merge it

Both re selected and then the button that allows me to merge the mesh and the relief lit up. I merged highest to make them one. The mesh could then be taken away.

The head will be routed as a separate piece out of a 3" block of 30 lb Precision Board. I'll be using this rough form to use an an armature for the sculpting with Abracadabra Sculpt that will follow.

To make sure everything was sized right I brought all the pieces together and positioned them as they would be glued after routing. Here's how that looked.

Now it is on to the MultiCam. Stay tuned...

-dan

Wavy banner

2012-01-17T15:49:00.000-08:00

The ballon will be 'towing' a wavy banner that has our name on it. This is advertising after all.

I decided it would wave both vertically and horizontally for maximum effect. And a quick measure showed a 4 foot long banner was the right size. I created the basic vectors and lettering in Illustrator and then imported these to EnRoute.

The next step is to size everything (as one unit). Then I added a border around the letters using the outline tool.

I created a flat relief and then imported a bitmap called Splotches from my TEXTURE MAGIC collection. I selected the banner and the bitmap to light up the button shaped like a mountain and sky. I put in a value of 0.15 to create a subtle texture over the entire surface.

Then I selected the banner and the lettering outline to raise this area slightly from the background. If I had wanted this area to not have texture I would have built a separate relief and merged them later.

Last up was the slightly domed lettering which was raised 0.15 off the outline to make it easy to paint later.

The new MultiCam took care of the routing in a hurry. Then it was time to do a little bending. I had bought a heating blanket some months previous. It is controllable and will heat to 400 degrees. I put it under the banner with it raised off the table and let the heat soak in good. A full bucket of paint and block of Precision Board provided the weight I needed to provide the bending force.

When I was happy I turned off the heater and let things cool. The result was a banner that looks like it is flapping in the wind.

I mocked it up behind the balloon to check it out. And it looked pretty cool. Now it is on to paint.

Stay tuned for more progress...

-dan

Up, up and away!

2012-01-16T14:49:00.000-08:00

I assembled the nose cones with screws and PB Bond 240 - a one part glue from Coastal Enterprises. It is activated with a spritz of water and tends to expand some as it cures. this meant I would have to do a little cleanup and shaping with mu die grinder but this was no problem as I intended to cover the nose cones with some Abracadabra Sculpt to add some details.

The covering on the nose cones as well as the hand crafted cables around the balloon instantly took away from the machine made look - just what I wanted. the balloon now matched the gondola underneath.

Once the epoxy sculpting medium had cured to was time to apply a coat of FSC-88 WB primer. This primer is heavy bodies water base primer from Coastal Enterprises. I applied it by hand with a small brush to introduce a little more texture over the entire surface.

And once the primer had cured it was time to start in on some color. I'll be using all acrylic paints as per our norm. The metallics are from Modern Masters and look great - even on the first coat. Everything will get a second cot and then I'll start in on the glazes to add depth and some aging. It makes me giggle when I see it in the shop. It is going to look pretty cool against our blue ceiling in the studio library.

Stay tuned for more progress.

-dan

Nose cone

2012-01-15T22:22:00.000-08:00

For the nose cones of the ballon I decided to use the 3 axis part of the router. It was a quicker way of doing things in this case. I first measured up the balloon to determine the angle and size of the nose cone, then began building the file in EnRoute. I would use the revolve tool to build a mesh and then convert this to a relief. The red lines below show how I lined things up to a box of known dimensions.

The screen shot below show the settings I used to create the mesh. I skipped the first screen where I selected the contour to be revolved command.

The mesh lights up red when selected and the view button is turned on.

I then drew a vector box around the mesh. I used this to create a zero height relief.

I selected both which allowed me to select the merge mesh to relief button. The round option allows the relief to be smoothed as desired. I left the smoothing amount in the middle. I also selected merge highest.

Then I hit apply and the screen capture shows how the red of the mesh peeks through a bit. I know the procedure worked as intended. I then deleted the mesh.

The next task was to create the slices I needed in order to fit my nose one pieces into a piece of 1.5" thick Precision Board. The screen shot below shows the perimeters I entered to create two slices. Doing s creates the slices I need without touching the original file.

I pulled out the two slices I needed and selected them and then moved them to the bottom of the plate.

Then I duplicated them to make four copies. I flipped over the top section so they fit together nicely.

I created an offset vector line of 0.7" around ill the pieces and then made a zero height relief. Then I merged the pieces of the nose cone to the new relief and then deleted the cone pieces.

This created the routing file I would need.

I tool pathed the file with a single pass using a 3/8" ball nose bit and an 80% overlap.

With the relatively large tool it didn't take long for the MultiCam to cut these parts.

Next up we'll glue them together and onto the balloon. After that is is time for a little sculpting to make it look like everything was hand made. Stay tuned...

-dan

Quilted balloon on 4 axis router

2012-01-14T22:17:00.000-08:00

On Friday it was time to put our first real project on the four axis MultiCam and give it a whirl. IT would be the hot air balloon. We would cut it from a large block of 30 lb Precision Board measuring 14" x 14" x 20 " long. We had previously drilled a hole in the center of each end and driven in a pipe. This would be our clamping point for the lathe. The routing operation would be in three phases. The first was the true lathe mode. Here we would assign a steady feed rate for the y axis. The z feed would be done in three passes as a straight line across the piece each time. The second operation was the roughing done in four passes. This was done with a half inch ball nose bit with a 50% overlap. The final operation was the cleanup pass done with a 3/8" ball nose bit and a 95% overlap. A higher than typical overlap was necessary because the piece had a big diameter and the degree of rotation meant a greater distance corresponding to the distance from the centerline. Here's a short video showing the various passes...

As soon as the piece was done I removed the steel pipes, drilled a hole and mounted it to the driver's cab. It was looking pretty close to my illustration already.

in the next installment we'll be designing and routing the nose and tail cones for the balloon to finish off the sculpting process. Then it is off to the paint department. Stay tuned...

-dan

What if?

2012-01-12T22:39:00.000-08:00

Today was a day of WHAT IFS! Sean Kirsch and Craig Sior had worked out all the hickups on the MultiCam fourth axis machine and now it was time to start figuring out the things that were now possible. We started with a basic barrel shape. A raised and bevelled letter A was added for good measure.

While this file was proved on the machine someone asked for a bent branch with textured bark. It took some figuring out how to achieve it but using a mesh created in EnRoute and then merging it to the relief and then adding healthy texture from the TEXTURE MAGIC collection we were able to achieve it. Each time a file was sent to the router everyone would rush from my office to see the MAGIC happen first time on the machine. As the file was slowly revealed by the router a high five would be the celebration and a new idea - even wilder than the last was immediately brought forward to raise the bar once more.

Then Mark Hurt asked the question whether we could fabricate a column with Rapid Texture wrapped around it... matching perfectly on the join line and on each end so they could be stacked. It ooh a little head scratching but within a short time the file was ready to test on the MultiCam. Huge grins and high fives were again the order of the day as this test was successful.

With the setting up and numerous tests now complete our minds race to the future. Each step fuels wonderful ideas of the next step and the step after that. A whole new world of possibilities suddenly opens up. What is possible?

Anything we can imagine!

-dan

Week of discovery

2012-01-12T01:15:00.000-08:00

Six years ago I clearly remember the day we pushed the GO button on our first 3D project on our new MultiCam router. It was with pure wonder and amazement as I watched the router magically go back and forth on our block of Precision Board and revealed a piece of art within.

This week we were privileged to host a gathering of some extremely creative and intelligent people, some of the leaders in the routing world. We were joined by Jeff Hartman, one of the creators of EnRoute Software, Shawn Kirsch, head of product development at MultiCam, Craig Sior, motion control engineer from MultiCam, and Mark Hurt, a MultiCam power user from Hawaii. The purpose of our three day gathering was to both start the first 4 axis projects on our new machine and to talk about what is going to happen from this point forward.

Machine parameters had to be set, dependent on how we were going to use the machine. Every possible facet of the four axis operation was discussed. Initial goals were modest and logical but it wasn't long until more and more complex projects and possibilities were being tossed out. One idea led to another and to another and to another. All was done in good humor and good company.

The first project we put on the new machine was an oversized Coke bottle. I had designed the file a while back, but now was to time to prove the theory and make it all real. As it happened six years ago when I watched the MultiCam route our very first 3D piece the MAGIC was about to begin once more. We chucked up the block in the rotary attachment and set the machine in motion. Here's what happened...

We first used the router in full lathe mode to round the block. Then we used a 3/8" ball nose bit to create the Coke bottle. It took some experimentation to determine overlaps needed to provide a smooth surface. Once the machine had dome it's first pass at the magic we ordered a second pass on select areas with a 1/8" ball nose bit to clean up the lettering and bottle cap.

While far from perfect, the first piece off the router was cause for great celebration. We had gone from zero to sixty in only two short days. Tomorrow the discussion and dreaming continues. Most of the technical talk goes far over my head. No matter. It is one of the greatest of opportunities ever. The new software and capabilities of the four axis MultiCam and EnRoute software will be driven from both an artistic and technical point of view. The creators of the machine and software are working together with myself and others to go far and fast towards endless creative possibilities.

This week five folks put their heads together to see what is currently possible and more importantly to discuss the future direction things will go. This is but the first of many pieces we will do. Already there are far more exciting projects in the planning stages. The folks at MultiCam and EnRoute are working hard to figure out ways to make it possible for us to bring these visions to life on the CNC router. While I watched in awe the first time I saw the machine magically operate six years ago, this time around is even more wondrous for I now am starting to understand the hard work, endless trial and error, and incredible behind the scenes labor and thought required to make this magic possible.

The three days together will only be the starting point of this exciting adventure. Now the real work begins as the folks at MultiCam and EnRoute create a working software pared with the machine to allow myself and a host of others to create our artistic visions relatively easily by inputting our ideas into a simple interface on our computers. It will certainly take considerable time and effort to achieve.

But the journey has begun for real!

-dan

Ye olde cellar door

2012-01-09T11:23:00.000-08:00

There is a large white metal door behind the Fox & Hounds Pub bar that looks sorely out of place. The door leads to the large cooler that holds all the beer. Our task is to make it fit into the rest of the decor. The solution was to route a door skin from 40 lb Precision Board which we'll fasten to the door.

The hardware (hinges and closures) was not movable. We had to work around them. Because the door is high traffic we decided to stay away from the edges 3". This will minimize the chances of damage down the road. I drew up a template in EnRoute from careful measurements taken on site.

The next step was to create the individual planks for the wood grained door. I first drew the gaps between the planks, then used the jigsaw tool to create the individual planks. This was the fastest way to get everything to line up as it should.

Square rivet heads (with rounded corners) were next to be added.

I used the horizontal and vertical woodgrain bitmaps from my TEXTURE MAGIC collection to create the woodgrains. The bitmaps were enlarged enough to fit across each plank and then applied with a value of 0.15" for the depth.

The result was some pleasing woodgrain that looked cool already.

The next step was to create the rivets. These were created as separate reliefs using the bevel tool. Once I had floated them into position I merged highest to make them part of the door panel.

The name plate was the next order of business. It was a simple oval shape. with some round rivets.

I used another bitmap from the TEXTURE MAGIC collection called splotches 1 to create a beaten copper look for the name plate.

Then I added a low lettering border and the beveled lettering as a last step.

As quick as that the door skin was ready for tool pathing. I did a rough pass with a 3/8" ball nose bit at 50% and then a final pass with a 1/8" with a 75% overlap. Then I sent it to the MultiCam.

Next up is the finishing. While it routes I'll be working on one more very cool sign for the pub. Stay tuned...

-dan

The end of the lathe saga

2012-01-08T13:39:00.000-08:00

I am often labled as a very smart guy and on occasion I even hear the word genius. I like to think so too. :) But my family and friends know otherwise and often remind me and anyone who will listen of some of my bigger goofs to prove it. I am forced to admit here have been a few through the years.

Back in the mid 80's I decided I desparately needed a lathe. My selection of tools was meager at best. We didn't have a lot of money. It took more than a little convincing to get Janis to agree, but I did my homework and found a sturdy lathe that would do the job. There was one problem however. The model we could afford was too short for what I had in mind. When I got it home I didn't assemble it. Rather I cut it into pieces and then welded up a longer frame. Now those who know me know I am somewhat challenged to get things straight or level. Some would argue I am SEVERELY challenged. But I got it pretty straight. Or at least as straight as I could manage. I bolted the lathe together and set to work.

It worked well, as long as I continually kept things snugged up. The two ends weren't quite in line and so the piece being turned had a tendency to loosten up a little as I worked. But I learned to deal with it and did some very fine work. At least that is my recollection of events. My family remembers things differently and with great glee remind me of 'THE LATHE' at every opportunity.

I have to admit that the truth is in the 25 years (or so) I had the machine it never did a paying job. I did a couple of study models with it although sadly I only have one to prove it at this point. My family says there only was this one. No matter. I know what really happened for I was there.

The lathe has languished in my shop for many years, gathering dust in a corner. Each time it gets in the way it gets moved, but never to a convenient place. I've always promised myself that some day soon I'll take the time to cut the frame apart, straighten it out, weld it back together and then put it to good use. But life is busy and it didn't happen (YET).

With the arrival of the new MultiCam CNC router with the fourth axis I will never need the lathe again. The new tool is perfectly straight and accurate. I have no intention of modifying it. I can build the files on my desk and then send them to the machine. And at last I can build massive things - much bigger than the old lathe could have handled. It was time to find the old (almost as new) lathe a new home. I considered selling it but that would have reminded Janis of how much it had cost us to own this thing. She is very good at math. I considered leaving it to my son Peter in my will. He teased me the most about my reassembly of the precision instrument and his very skewed version how it operated. I would have stipulated that he could never ever get rid of it as a way of having the last laugh in this matter. But I reconsidered for I want him to remember me with some good stuff I realized that if he had the lathe he would claim to have the proof of his version of the story. We couldn't have that. I decided I would instead give it to Phoenix and not wait any longer. I dragged it out from the corner, dusted it off and loaded it into the truck. My son-in-law Phoenix is good at getting things much straighter than I ever could. He has a welder to get it right. And no doubt he'll put the machine to good use.

I'll welcome the extra floor space we've opened up in our shop. I'll also sleep well knowing my 'favorite' tool is going to a good home.

Now that the lathe is gone maybe my family will forget this episode... but then again probably not. Chances are, like all good stories it will grow in time to become something that will be told again and again when the time is right. As always, I prefer my (true) version of the story.

-grampa dan

Things go better with Coke!

2012-01-07T21:42:00.000-08:00

Back in May I posted this how-to. Since then I've reworked it a bit with a better understanding of how it all works. In a few days we get to try out the file!

Like the files we currently build in EnRoute for our three axis MultiCam, I am discovering there are no end of solutions of how it will be done for the four axis router when we get it next month. Many of the four axis tasks will build on the capabilities of the current software. In many instances the files can be build as they are now and then the reliefs simply wrapped to form the fourth axis files. A thorough understanding of the current software will give us a leg up on what is to follow.

In the last months I have been searching the net to find out just what folks are doing and how they are doing it. What I have found out is many are using '3D clipart' and simply modifying the files to route in the round. It's not that much different than what is happening in the 3 axis world of routing. But I want to do a whole lot more than that. I want to build anything I can dream up. Even with the very limited things I have thought and dreamed up so far I believe I will be able to use EnRoute to achieve most of what I imagine for the four xis router. And since I've discovered that many things that some told me would be difficult or impossible to do on a three axis machine were indeed possible - imagine what will be possible with the four axis machine now in my shop.

As I sipped a Coke and did some sketching it occurred to me how difficult something like a Coke bottle would be with a three axis router. Difficult but not impossible. But with a four axis setup it suddenly became relatively easy. As usual it is as simple as visualizing the various bits and then combning them for the finished result. Let me take you through the process...

It only took a few seconds to locate a good picture on the net of the Coke bottle I wanted. It was the old style with embossed lettering. I also located a bitmap Coke logo. I did a vector trace of the bitmap image of the logo and hand traced the bottle profile in a few seconds more. EnRoute is very good at that task.

Sweep to rails is a task I am now familiar and comfortable with. It looked like a flattened Coke bottle already. This was merged with a zero height relief.

Now it was time to add the flutes. I lined the Coke bottle picture up with the relief and drew two appropriately sized shapes...

These were then duplicated across the bottle. I counted the number of flutes on a real bottle and then sized and spaced then accordingly. I then modified my relief to form very subtle flutes across the bottle.

The lettering was next. Unfortunately I neglected to grab a screen capture of the vectors for the next picture. I squished them together to deform them horizontally. The thing to remember is that as we wrap around the center axis the thicker part of the bottle will stretch out the surface (by virtue of its distance from the center axis), bringing the lettering back to it's proper shape.

The bottle cap was next. I created a zero height relief and then modified it with the oval shapes. I made them 1" tall and domed steeply. The parts sticking off of the zero height relief were cut off sharply when I merged them of course.

I checked the side view and saw they needed tapering at the top.

I chose to modify them with a fade bitmap It worked out to be 0.6" that made them blend into the top of the bottle cap.

The next shot shows how the blend bitmap affected the ridges of the bottle cap.

I then resized and positioned the file before merging it with the original relief. Except for wrapping it around the center axis the file was complete. This screen shot shows how the lettering was squished horizontally in the original file. As it wraps it gets stretched out appropriately.

The MultiCam drivers will convert the flat file I made in EnRoute to wrap around the centerline of the bottle instead of moving in the X axis like it does on a flatbed router. Until I show the result on the router here's a simulation of roughly how it will look.

-dan

Spring Sign Magic Workshop fast approaching!

2012-01-07T18:43:00.000-08:00

It is hard to believe but the Spring 2012 Sign Magic Workshop is now just over two short months away. Amazingly it will be the twelfth such workshop we have hosted in our studio. We already have folks signed up from as far away as Pennsylvania. There is lots of interest and a few seats are still available.

If you wish more information visit our website SIGN MAGIC WORKSHOP or drop me an email at dan@imaginationcorporation.com

I'm looking forward to one more great workshop!

-dan

Building a balloon (in 3D)

2012-01-05T21:56:00.000-08:00

Four axis routing is not much different that three axis machining. Instead of moving the router head across my table (X axis) the rotary axis rotates the work in minute degrees while the spindle travels up and down the piece in the horizontal and vertical planes. Y & Z axis) The good news is the software does all this work for us. All we have to do is build the files.

The trick is to know (and understand) what is happening and how it affects our design. For the most part (currently) we will build the designs as we always have. The key is both sides of the design must match or it will look funny was the design is wrapped around a center line. The join line needs to be invisible to be right The second factor to remember is that for 3D designs the further we get from the center axis the more things will stretch out as they are wrapped. The key is a little math to figure out circumferences and the like. I am sure there are formulas to calculate the amount of stretching that will occur at each distance from the center but I tend to do this by trial and error, learning by hands-on experience. It has been a lot of years for me since I did any math remotely like this. The good news is the internet and calculators makes finding the basic solutions to the math relatively easy these days.

Like all aspects of 3D design there is a definite learning curve and this is definitely a little trickier than flat work - but if I can get my head around it most should have no trouble with it after lots of practice and a little trial and error. Luckily I have a super sized garbage bin. I filled it often when I first started routing and I suspect that time is upon us one more.

For the balloon we want each section to pillow out as well as have the middle section much fatter than the ends. The cones will be routed and installed separately. It is just easier and quicker that way. Since the ends taper to almost point a lot of material and machine time would be used up for little effect by doing it in one go. I started the balloon with diamond vectors and a vector rectangle of the size I needed.

My block of Precision Board is 14" square on the end and 20 inches long. The balloon would taper to 6" diameter on the end meaning the circumference is 6" x 3.1416 The plate for the balloon would measure 18.8496" W x 19" H. Then I set to work. Everything would be done inside EnRoute.

I built a diamond shaped grid, making sure the corners of the diamond shapes went through the corners of the rectangle. I pulled these lines to the side and used the jigsaw tool to extract the diamonds as individual shapes, then deleted the lines. Then I used the offset tool to create smaller diamonds inside those. These would be the basis for the pillow shaped puffiness of the balloon.

Then I deleted the lines and lined everything up just right.

Then I drew an oval in the center. This is where the balloon will hook up to the hot air pipe from the gondola. The jigsaw tool was again used to trim the surrounding diamonds to fit.

Then I built the plate. The end diamonds were flat reliefs added to the original plate. Then I built the puffy diamonds in the center using the dome tool. I forgot to get a screen shot of that stage but it is pretty simple. At this point the relief is still flat with the puffy diamond pillows.

Then it was time to build up the center of the ballon to make it look like it was inflated. I knew I wanted a 3" high arch so I built a 3" x 19" box. I used this as a guide to create a curved vector line which would be used in the next stage - sweep two rails. I also created the two vertical vector lines that hug each side of the relief.

I used these lines with the sweep to rails function and got a mesh that looks like this.

Once I had added the mesh to the relief it formed the arch I wanted.

When I looked at it at this point I realized I had made a serious mistake. On reviewing my notes I discovered I had calculated the circumference incorrectly and for some reason had made the file only twelve point something high instead of the required 18.8496" It was a simple matter of stretching it out to size. I actually liked the shape of the diamond better and since I was in charge I made an executive decision to forge on ahead. I wouldn't have to start over.

In 3D view it looked like this. The end towards the viewer would wrap around to meet the other side and form the balloon shape I wanted.

To run the file on my new four axis MultiCam I tool path the file as I would any conventional 3D file in EnRoute. I used a half inch ballnose bit with a 50% overlap for the rough pass and a 3/8" ball nose bit with a 90% overlap for the final. All speeds were set at 300 inches per minute. The MultiCam software takes the G-code and converts it for the round axis automatically. Next week I'll show a movie of this file running on the machine.

In the mean time as a teaser I show you a wireframe simulation of the balloon as it will look when it is cut. (side view)

This makes me smile. Imagine where we will go from here...

Stay tuned...

-dan

EXCITING WEEK PLANNED!

2012-01-04T17:03:00.000-08:00

Next week promises to be an exciting one! Before Christmas our new four axis 3000 series MultiCam was installed in our shop. It is working perfectly and is unbelievably fast! Our MultiCam representative from Texas, Shawn Kirsch got everything going but ran out of time to train me properly in the operation of the new fourth axis. With my limited technical knowhow it was best I stay away from the new feature until I knew more. Next week Shawn comes back to give me the training I need to get into operation. I can hardly wait.

Over the last days I have cut and glued up some 30 lb Precision Board blocks of various sizes to chuck up in the machine. The bottom large block is for the project below. It measures fourteen inches square by twenty inches long. The pipes sticking out of the ends of the blocks are for chucking them up in the machine.

I've been working on some files as well. A number of months ago I started a cool demonstration piece for the router and our shop. I talked about it here... fantasy dirigible

Well' things got busy and the project was pushed to the back burner... until today. Now it is time to dust it off and get ready to do some serious 3D routing.

When we left the project a while back I had welded up the steel frame and started in on the sculpt.

I got along fairly well and will finish the bulk of the sculpt of this part later tonight.

I also did a quick comp/sketch of the balloon to visualize how it would look hanging in my studio. I know it will fit right in.

My next post will describe how I built the routing file to create the balloon. Stay tuned...

-dan

Movie of glazing process

2012-01-03T16:49:00.000-08:00

Writing about the glazing process never seems to get enough information across to the readers. It is but one of the many things we teach in our workshops, best done with a demonstration and then practice.

Since I can't come to see you and how you are doing it a video will have to do here.

I also grabbed three photos of the sign after I had finished putting on the glaze. It shows in better detail how I wiped off the high points, leaving the glazes in the lows.

Once the glaze was dry I went back and put a couple of coats of the Modern Masters metallic gold on the top surface of the lettering to finish off the sign.

So hopefully this little video answers a few more questions for everybody.

-dan

COLOR!

2012-01-03T11:48:00.000-08:00

This morning I brushed a coat of the thick Coastal Enterprises FSC-88 WB primer onto the piece. In some areas I used it to smooth things out, while in others the primer was used to add a little texture. As per their instructions I put a fan onto the piece and did something else while it dried.

Then I painted on two coats of a water based gold metallic paint (Modern Masters) He was looking pretty solid and rich looking at this point. This paint was also brushed on an allowed to dry thoroughly between coats. I made sure I painted well onto the areas that would be getting the next color. This meant I would only have to cut once, saving time.

Then I added the color to the border using a rich red metallic (also Modern Masters paint) I used the raised ridge as a cut line making the job easy and quick.

I have a fan on the piece now and it will stay there until this afternoon sometime. Then I'll start adding the glazes which will bring this piece alive in a few minutes. I'll be posting pictures and maybe even a movie of that process to show just how easy it is. Stay tuned...

-dan

He's a good, traditional chap.

2012-01-02T23:11:00.000-08:00

The legend has it that the 'founder' of the Fox and Hounds Pub was a very traditional, Victorian and VERY proper British chap. An image quickly came to my mind. Today I spent about an hour and a half pressing a thin layer of Abracadabra sculpting epoxy onto the routed head and then using my fingers and a sharpened stick carving the details in. With the sturdy Precision Board underneath to guide me it was relatively easy to form the head and get both sides of his face symmetrical and even. I worked from the bottom upwards so I could wet my fingers and tools in water to smooth things out without the sculpt sticking.

Tomorrow everything will be rock hard and ready for the paint. I am leaning towards making it look like a weathered bronze sculpt at this point. Sleeping on it may just help me make up my mind.

-dan

Routing my first sculpted 3D file

2012-01-01T21:34:00.000-08:00

Happy New Year!

It's a holiday today and so I came out to the shop to just play a bit. Over the holidays I've been working on 3D files and then trying to figure out how to export them so they can be used in EnRoute. As usual there is a brutal learning curve. And I'm struggling through it by sheer force - as always.

In making the files I was so intent on what I was doing I didn't do any screen captures. At this point I am so mixed up it would most likely just confuse everyone in any case. But in spite of myself I am getting some results I like. I am working on a piece that honors the Fox & Hounds Pub's 'founder'. He's a fictitious dude - as is the date of the founding but it is fun never-the-less. I'm hoping the owners will like him enough to hang the sign in the food service area by the cash register near the restaurant.

I created the 3D mesh in a program called ZBrush. If you think EnRoute is complicated don't even try ZBrush. It makes my head hurt. But I did manage to churn out a mesh file I kinda liked. It will take a little hand sculpting to make it usable. ZBrush doesn't export in a format EnRoute can use, but a trial copy of Rhino did the conversion to DXF that I needed. Then I made it into a relief in EnRoute and tool pathed it using a 1/2" ball nose bit. Because I was whittling it from a 3" thick block of 40lb Precision Board I needed some serious length in the bit and the 1/2" did the trick. I wasn't worried about detail as I'll carve and sculpt that in later. Here's a quick movie of the MultiCam in action on the 3D file

While the face was being cut I whipped up a background plate and lettering oval for the sign. This was pretty standard stuff using a few of the bitmap textures from my TEXTURE MAGIC collection. The lettering is prismatic. I routed it in two layers so I would get the depth I needed to accommodate the 3D head of the pub founder.

I'll be sculpting in the neck and shoulders by hand as well as a little more detail throughout.

The sign looks good in it's rough state but will hopefully have a lot more impact by the time it is finished. I'll be back to post pictures of the progress. Stay tuned...

-dan

We'll leave the lights on

2011-12-30T20:51:00.000-08:00

There are few things that add more sparkle to a sign more than lights. With the advent of modern LED lighting it is now possible to include lighting in ways we could only dream of years ago. Now it is easy, safe and economical.

I found a new lighting system a couple of years ago that looked promising. It is called Heico Lighting It was a while before I had a chance to try them. Late last year on the MultiCam office project was the first time MultiCam Sub I got a chance to really give them a test drive. I was impressed to say the least. After a year in operation they still are just as amazing and still work perfectly.

What is different about these little lights is how easy they are to install. No advance planning is necessary for they just slip over the low voltage wire without even connecting them. One small transformer can power 1-350 of the modules. A slightly larger model can handle more than double that number of lights.

We hear many guarantees these days promising the moon and more. Sadly it isn't always factual. This time I believe the claims to all be true. Early in 2011 I had a chance to sit down for a long talk with some of the folks at Heico lighting. They are a small company in eastern Canada that actually makes their own products and doesn't merely have someone in China do it. They promise five years of trouble free operation and they back it up too. That is a very rare thing these days.

I couldn't resist adding some of these little lights to brighten the windows of the Rovers Return Inn sign. Peter and I picked up some white plexiglass today, cut it to size and popped the pieces into the window frames from the rear. Then we tested out a couple colors of the Heico lighting modules. We both agreed the amber added the perfect warm glow. Five modules would do the trick. Here's a shot of the back of the sign to show how things were laid out.

At the last minute I decided to add gold to the Rovers Return sign as in some of the reference photos it appeared that way. It added a little more bling to the piece. The glowing windows was the crowning touch. In the subdued light of the pub this sign is going to look stunning! One more piece of eye candy is now ready to hang at the Fox and Hounds Pub.

I'll be doing a step by step on some cool upcoming projects that are designed to take full advantage of this wonderful lighting technology in the next few weeks so watch for it...

-dan

Marketing - seven year old style

2011-12-29T22:52:00.000-08:00

Phoebe (my seven year old grand daughter) is big into 'owning and operating' a store these days. All through the holidays she has been busy producing copious amounts of drawings and other art and then selling them to relatives - especially her grampa. The proceeds she is donating to Pipsqueak Paddocks. (her idea). www.pipsqueakpaddocks.com She has a table set up in the play room. The art is carefully laid out in an elaborate display. Paper signs she has designed and colored are taped to the walls. Hand drawn business cards (complete with her own logo) with all her information are handed out to those she meets to spread the word of her enterprise.

Since before Christmas she has been asking if I could please make her a real dimensional sign. I of course said yes but needed a design. Today she was helping in the shop and she went into the studio for a long time while I was busy. She came out with a design in hand - all excuses were gone.

Dragons seem to be Phoebe's current interest and so her sign features a nice one - holding a sign with her name on it. She explained the design at great length to me. It would be 24" wide and showed me how big that would be with her very own tape measure. The sky (background) would be blue. The sun would have to be yellow (like in all her drawings) The dragon would be colored as pictured. It needed hangers with real chains so it would be very strong. And I was not to worry about the details for she would help me as we got that far into the production of the sign. She also set a deadline. Could I please have the sign ready in 3 days? I told her it would indeed be possible if she helped me.

With Phoebe looking carefully over my shoulder I painstakingly drew out the vector art I would need to do the routing file for her sign. She corrected me when I strayed too far from her original design.

Then I created the routing file which we'll put on the machine tomorrow. The file was pretty basic. To create a childlike sculpture of Phoebe's dragon I simply let the software determine the shape of the rounded body. The exception was the mouth which I formed by merging (lowest) a wedge shaped piece of zero height. The scales on the dragon's back were flat reliefs. All the reliefs were built separately , moved to the right height and then merged highest for form the 3D picture Phoebe was after.

Phoebe is very excited about finishing her very first sign! Stay tuned...

-grampa dan

Painting and glazing brings projects alive

2011-12-29T22:13:00.000-08:00

Paint can make or break any design. And the glazes are the difference between a sign that looks plastic and new to one that has character, depth and age. The picture below shows how the Rovers Return sign looked when we finished the base colors. The building looked crisp and new, but also looked too flat. The brick lines were weak and didn't catch the light as they should.

For the glaze I added some clear base and a bit of water to make it flow, then slopped on a coat of the grungy, dark brown and then wiped it off judiciously with a soft towel. The building instantly came to life. Every crack. crevice and bit of texture suddenly became evident. The building looked like it had been there for a long, long time. I still have to add the lettering on the two small signs.

The plexiglass windows still have to be glued in and I'll be installing some LED lights to make it look like the building is occupied. Stay tuned...

-dan

Sculpting done on the Rovers Return sign

2011-12-28T20:02:00.000-08:00

Today was organization day in the shop. My son Peter, who is on Christmas break from university gave me a hand. First we put away tools and supplies - all to their proper home. Then it was time to do a project I've been wanting to do for some time - The sculpting on the Rovers Return Pub sign. Peter is an accomplished artist in his own right. He worked as a team leader for us for more than 14 years. He handled the brickwork on the front of the tiny building while I handled the rest. We jockied positions, switching sides as necessary to get into the tight spaces. With two skilled hands at work the building was done in a short while. In this shot Peter is adding texture to the small bricks using an old toothbrush.

Tomorrow the final texturing of the base portion of the sign will be done using a die grinder. Then we will add Coastal Enterprises primer and final coats of paint and glazes. Stay tuned...

-dan

Another piece installed.

2011-12-27T15:09:00.000-08:00

Today we made a quick trip to the Fox and Hounds to install the scroll on the stage. New Year's celebrations are only days away and all eyes will be on the stage during that event.

Peter & I bundled the finished piece and stopped it into the back of the pickup. Installations went quick and easy. We lifted it into place, centered and leveled it before drilling the holes and fastening it to the wall. Some carefully placed holes were drilled through the sign and faux cement bricks, before some long wood screws were popped into place. We were done as quick as that, finishing off another area of the pub. The weathered and textured scroll looks great with the bricks and the chainsaw carved wooden sculptures of the Fox and Hounds (done by others).

A good picture was impossible with the lighting present and the pocket camera I had handy as they come out either washed out or too dark. In person it looks fabulous and fits in perfectly with everything else.

Today we are having a somewhat lazy day, easing back into the work flow. Tomorrow we'll begin once again in earnest.

-dan

Merry Christmas to ALL!

2011-12-24T16:24:00.000-08:00

I just wanted to say thank you for supporting my efforts here on this blog. I always appreciate the comments, questions and suggestions. It was good to meet in person those I did at trade shows, workshops or elsewhere. I look forward to meeting more of you in the future.

As we wind things down for a few days of holidays I want to take this opportunity to wish each of you a Merry Christmas. I hope you get to spend some time with those you love, friends and family this season.
Once I've consumed my share of roast turkey and many other good things I'll be back in the shop doing my best to work it all off. :)

We have some very exciting things in store for the New Year, including some projects on the new four axis MultiCam.

I would like to especially thank the folks at MultiCam for helping to make this blog possible.

Merry Christmas to ALL!

-dan

Tap dancing part two

2011-12-24T14:00:00.000-08:00

The tap file was programed with tool speeds of 300 inches per minute horizontally, 150 inches per minute vertically. I've been doing it this way for years. The reality is however that unless your machine is capable of accelerating and decelerating quickly it will never reach these kinds of speeds on a file like this. I was pleased with my six year old MultiCam, especially after my tech tuned the parameters for the types of files we were running. But when I fired up the new 3000 series MultiCam I discovered just how much faster they have made the machine in the last years. This machine was dialed in from the factory for my kind of routing.

If you have trouble with the embedded video here's the tube link.
http://www.youtube.com/watch?v=5pik629XB88

And before I knew it the file was run. Four taps in two sizes were ready for paint.

-dan

Tap dancing!

2011-12-24T13:49:00.000-08:00

At the Fox and Hounds Pub there is a small area above the bar cooler door that we left a couple of plastic pipes exposed. Our intent is to make them into some funky copper plumbing with a variety of taps. What their actual 'function' might be is mysterious but it will be an interesting vignette. I was going to use some real taps but decided instead to just route some from 30 lb Precision Board. It will save me time and I will also get exactly what I need for the job.

This is the kind of project I enjoy, figuring out how to make these complex shapes in EnRoute. I decided the taps would be six sided so I first created the spokes of the tap, some concentric circles and the smaller circles which I would use as guidelines for my final shape. I know there is a way to position the circles around the outside automatically but I couldn't remember so I did it by hnd. In=For this file total accuracy wasn't critical.

Then I used the drawing tool and drew a12 sided shape using the intersecting points of the smaller circles as my reference points. Then I used the line editing tool to bend them to the right shape using the small circles as reference. Then I could delete the circles.

I used the offset tool to build the inside rim of the tap and shortened the spokes, and finally rounded their ends. I created one more offset to use as my zero height relief on which I would build the file. I like to route my small parts in this fashion as if I purposely leave an onion skin on the bottom the parts stay on the table securely.

The zero height background relief was the first step. then I added the rim of the tap as shown.

The spokes were next but built as a separate piece. They would be merged highest later.

Then I built the center section using the bevel tool but limiting the height to create a flat top and bevelled edge.

Then I modified this relief with a tapered hole in the center. It will guide me when I drill for a piece of doweling later. I could have drilled it with the router but I haven't decided the size yet.

At this point everything was merged (highest) with the zero height relief. Too pathing was easy on this piece. Since there isn't any real detail and I wanted the inside corners to have a slight radius I decided to route it with only one tool - a 3/8 ball nose bit. The taps are to be machined from 30 lb Precision Board so they could be done in one pass. I used an 80 % overlap.

In the next post I'll show the pics of the finished project and a short movie to show just how FAST the new MultiCam handled the task.

-dan

Hailey's first sign is done

2011-12-23T19:21:00.000-08:00

Hailey was actually off today but at 8:00 am when I unlocked the shop doors she was there waiting. today was the day she would put the finishing touches to her first sign. It used all the tricks and techniques we have used for the Fox and Hounds project. She used the die grinder, sander, she sculpted, primed and painted. The there was a little twisting of wire for the knarly tree and layers of colored glaze to tone it all down, tie it together and make it look old.

Christmas morning Hailey will proudly give it away to her beloved grandparents. The sign is for the family cottage by the ocean. She has a right to be proud too for it is a nice looking sign.

Well done!

-dan

Ready for paint

2011-12-22T12:04:00.000-08:00

This morning Hailey was at the shop bright and early, eager to work on her Christmas present. That was good for it meant I would be kept on schedule as well. We decided I would work on mine and then she would follow, doing as much as possible on hers. I cleaned up the glue line between the front and back pieces with the die grinder, then added a little texture to the sides and back of the base. She followed as soon as I was done. Then we mixed up a little Abracadabra Sculpting epoxy to fashion the bush along side of the lighthouse. We used an old tooth brush to add in the texture. The shingles were the next addition to the roof, also done with sculpting epoxy.

Then I took nine strands of tie wire and clamped them in my vice. I used a pair of pliers to twist them into a tree shape, branching out as we got towards the ends. Once the the was formed I drilled a hole in the rocks, filled it with sculpt and then pushed in my wire tree. Some twisted bits of sculpt formed some convincing roots around the base. As quick as that the sign was ready for paint.

Here's a pic of Hailey sculpting the roots of her tree...

And here's a shot of my sign ready to be primed and painted.

I'll post some more pictures later of it being painted.

-dan

Never too late

2011-12-21T23:05:00.000-08:00

With Christmas mere days away now it is almost past time to get the last of the Christmas presents ready for the big day. Hailey, one of our employees reminded me today that I had promised to help her make a lighthouse name plate for someone on her Christmas list. This year I have my sister-in-law as my person to buy/make a gift for and I just hadn't got there yet. I know she loves lighthouses as well so this was a golden opportunity to kill two birds with a single stone.

I first built the vectors for the two different names. I would add the same lighthouse to both plaques as a second step. The lighthouse would be created using the rotate/extrude tool. The lighthouse profile is simply wound around an axis to create a mesh.

Since meshes can't be tool pathed the next step was to create a flat, zero height relief and then merge the mesh to the relief. The menu is made live by selecting both the relief and the mesh. If you look close at the menu in the picture you will see I have not yet selected MERGE HIGHEST instead of add to relief.

After you do the merging the file will look like this. Then I selected the mesh (which is still there) and deleted it.

Then I opened the create slices menu to slice the flat relief from the lighthouse as shown below.

Slicing the rleif creates new slices without destroying or modifying the original file.

The lighthouse was then resized and places where I wanted it to be in relation to the rest of the sign. To create a faceted rock I created an irregular vector shape, then created a beveled relief using the limit to height command. This slices off the top nicely at a specified height.

The last relief I made was the name tags of he sign. I've shown this process many times before. If you wish to see it select 'Name plaques' from the previous posts. Before I did this step I also created a blank copy which would be flipped to form the back side of the plaques. The next step was to merge everything together onto a single background.

The two plaques were slightly different sizes. I then arranged and tool pathed the reliefs before sending them to the MultiCam. I let the machine do its job while we went out to supper to celebrate my grand daughter Phoebe's seventh birthday.

The files had been routed from 30 lb 1.5" thick Precision Board. I blew off the dust and using the PB Bond-240 one part glue I fastened and clamped the pieces together. By morning they will be plenty ready to finish up and paint - just in time for the big day.

Stay tuned for the finished pieces tomorrow.

-dan