new shaping machine part 2

New machines may work alot faster than old beasts, no? Typically a profesional CNC machine is set up to mill metal and be extremely accurate, thus slow. If you custommade such a machine for surfboard, milling foam only, you should be able do the cutting heaps faster. You can also take the symetry of the board into account. With two cutters working symetric about the centre axis, you cut the cutting time in half. Perhaps you can also lower the acuracy and increase power in the length direction of the board and work even faster.

regards,

Håvard

hi swaylockers,

behind the APS 3000 there is a team, Nev, Jimmy, Ralph and me, Miki. We watch your forum with some interest and I think it is about time that I step in and clarify the confusion a bit even it is a little late. Better late than never. I am what you would call an old fart in the industry. Yes, I can shape, glass and sand a board. Even make fins and stick them on. And as I am also an engineer, machines take my fancy. To give you an idea where I come from, here a small part of my CV: I have profiled way over 50 000 surfboards myself, starting off with a profiler over 20 years ago, worked with a hotwire CNC setup, designed, built and operated a pantograph (the thing that copies boards) and different kinds of CNC machines.

first up, yes you can do a surfboard on a shopbot. Will be a challenge but you will be very proud after you hold your first machined board in your hands. It will be an interesting experience and it would be nice if you share it with all of us in more detail. Show the board to a reputable shaper and have it judged with his experienced eyes. After you passed that hurdle we can look into reliability, consistency and later, the economics. But those things will have no importance for you anyway. And there are plenty more 3 axis overhead routers out there that can be used.

Second, I am sorry that I have to charge for my machine. To get this project of the ground I had to hand over my house to the bank and the family wants it back.

Next, surface finish. Here on the Gold Coast we have all major machines present. I can go and have a look. All of these machines except one are based on overhead routers with very much the same cutter. And these cutters, that is their nature, leave grooves way below the lowest point of the crinkle. The lowest point of the crinkle is the surface of the board. If you have to work below that point you dramatically interfere with the intended shape. All these machines can make the crinkle finer but even if you run the cutter for a whole week over the blank, the problem with the sanding grooves below the surface will not go away. In reality, that little bit makes a hell of a difference. And what about the stringer? How much work needs to be done to get the stringer clean? How will that change the shape again?

But most importantly, where is the custom board in all of this? The reason why my cutomers like what I offer is the fact that each board on my machine is made to order. No doubles for economic reasons ever. Each board is designed and machined specific to order (and his file kept on record for further reference) and to achieve that you have to do much more than steal the design of a green machine and paint it blue. At Base for example you have five big name shapers who do not settle for second best. Just to make the team boards for them is a challenge I love to face every day. and boy, are they picky. Take Murray Burton for example. The biggest voice against machine shaping. But he loves this concept as it enables him to give his customers and teamriders the design he did set out to achieve. Pure custom built. By the way, I deliver 95% of the orders next day, 5% same day.

Now, how does the machine look like? No picture? What do you expect. Why should I give away 5 years of R&D for nothing. And in China and Thailand they would be dancing in the streets. That would be silly, wouldn’t it. But she is different to anything you know. From the holding to the cutting. Look at the result, thats all that counts.

But the heart of it all is the program. The shaper becomes the designer with total control and ease that is. It is a bit scary, I agree. but when Benz drove his “Motorwagen” at an incredible speed (single digit) from one village to the next, people were scared too. It is our intention to give away the design program for free. We will put it on the net and everybody can use it. Please be patient.

And what about the soul, the spirit of custom boards?? When I machined the big guns for Clint Kimmins (a whole set, starting with 10’4") my soul was in it and certainly Nev’s too. And when I delivered them everybody was amazed, standing around in disbelieve, touching and feeling. Its the same boys, the spirit is back. With this machine, the shaper puts the spirit back. The spirit of the custom board is stronger than ever.

have fun miki

Quote:

hi swaylockers,

behind the APS 3000 there is a team, Nev, Jimmy, Ralph and me, Miki. We watch your forum with some interest and I think it is about time that I step in and clarify the confusion a bit even it is a little late. Better late than never. I am what you would call an old fart in the industry. Yes, I can shape, glass and sand a board. Even make fins and stick them on. And as I am also an engineer, machines take my fancy. To give you an idea where I come from, here a small part of my CV: I have profiled way over 50 000 surfboards myself, starting off with a profiler over 20 years ago, worked with a hotwire CNC setup, designed, built and operated a pantograph (the thing that copies boards) and different kinds of CNC machines.

first up, yes you can do a surfboard on a shopbot. Will be a challenge but you will be very proud after you hold your first machined board in your hands. It will be an interesting experience and it would be nice if you share it with all of us in more detail. Show the board to a reputable shaper and have it judged with his experienced eyes. After you passed that hurdle we can look into reliability, consistency and later, the economics. But those things will have no importance for you anyway. And there are plenty more 3 axis overhead routers out there that can be used.

Second, I am sorry that I have to charge for my machine. To get this project of the ground I had to hand over my house to the bank and the family wants it back.

Next, surface finish. Here on the Gold Coast we have all major machines present. I can go and have a look. All of these machines except one are based on overhead routers with very much the same cutter. And these cutters, that is their nature, leave grooves way below the lowest point of the crinkle. The lowest point of the crinkle is the surface of the board. If you have to work below that point you dramatically interfere with the intended shape. All these machines can make the crinkle finer but even if you run the cutter for a whole week over the blank, the problem with the sanding grooves below the surface will not go away. In reality, that little bit makes a hell of a difference. And what about the stringer? How much work needs to be done to get the stringer clean? How will that change the shape again?

But most importantly, where is the custom board in all of this? The reason why my cutomers like what I offer is the fact that each board on my machine is made to order. No doubles for economic reasons ever. Each board is designed and machined specific to order (and his file kept on record for further reference) and to achieve that you have to do much more than steal the design of a green machine and paint it blue. At Base for example you have five big name shapers who do not settle for second best. Just to make the team boards for them is a challenge I love to face every day. and boy, are they picky. Take Murray Burton for example. The biggest voice against machine shaping. But he loves this concept as it enables him to give his customers and teamriders the design he did set out to achieve. Pure custom built. By the way, I deliver 95% of the orders next day, 5% same day.

Now, how does the machine look like? No picture? What do you expect. Why should I give away 5 years of R&D for nothing. And in China and Thailand they would be dancing in the streets. That would be silly, wouldn’t it. But she is different to anything you know. From the holding to the cutting. Look at the result, thats all that counts.

But the heart of it all is the program. The shaper becomes the designer with total control and ease that is. It is a bit scary, I agree. but when Benz drove his “Motorwagen” at an incredible speed (single digit) from one village to the next, people were scared too. It is our intention to give away the design program for free. We will put it on the net and everybody can use it. Please be patient.

And what about the soul, the spirit of custom boards?? When I machined the big guns for Clint Kimmins (a whole set, starting with 10’4") my soul was in it and certainly Nev’s too. And when I delivered them everybody was amazed, standing around in disbelieve, touching and feeling. Its the same boys, the spirit is back. With this machine, the shaper puts the spirit back. The spirit of the custom board is stronger than ever.

have fun miki

Impressive!

Miki,

Is there a mailing list for your company? I’d like to play with your software asap.

please be a little bit patient. I will keep you informed when I finished setting up the server. also have to write a little manual with pics.

I would never buy a machine that I couldn’t look at. If a customer is interested in buying the machine do they get pictures? But at the same time I understand, if your ideas arn’t complicated enough they will be easy to copy through a picture.

Does the machine index each blank for you? Does it know if the deck didn’t clean up? And does it flip it for you?

Also when are you going to incorporate an automatic blank changer? seems like it wouldn’t take too much if you have gotten this far.

There is no reason why the router based machines should cut below the crinkle. that is just poor programming if they are doing that.

I too would love to see your design software.

you are right, who would buy a machine he can not see. there are procedures in place to protect the buyer but mainly it is the result that counts. as I deal with a lot of reputable and experienced shapers and as I have done over 7000 individual boards on this machine I have built up a solid reputation.

Indexing the blank is done via the software. this guarantees perfect alignment as well as minimal cutting depth.

unfortunatelly I have to turn the blanks over by hand. doing this automated sounds easy but I treat every blank as an individual(as they are)and that would make the automation process difficult and expensive. in a small production environment automation of turnover and blank loading makes no economical sense, in a high production environment you have an operator. and he needs something to do.

router based machines leave sanding ridges and that can not be avoided due to their horizontal rotation and the fact that they rely on a sanding surface. except you operate all 5 axis. just have a look at the boards. and 5 axis machines are way out of reach for the surfboard industry. the mechanics would be very challenging too as the cutting forces on foam are much higher than generally anticipated. but if you have an idea how to solve those problems, please let me know as I have a killer cutter design for a 5 axis machine.

Hi Miki,

can you please give us an idea why and how your machine is technically different from other CNC machines?

regards,

Håvard

ok, here some hints on my little machine:

1.) from day one I wanted a machine to make individual custom boards. therefore I had to invent a blank holding system that is fast to load and respects the individuality of each blank as they are never the same. thats why I do not have 24 adjustment screws. also I wanted to be able to change blank sizes quickly, in a custom board environment you make for example a 62 then a 73, then a 8’mal and so on. hence I could not use 12 adjustment bars which have to be moved in position for each blank and readjusted…

next I had to invent a new cutting technique as the sanding heads of the machines I know create way too much pressure which you have to compensate with holding forces. blanks do not like holding forces and if you apply them anyway they will pop back later and your lines are history. as I wanted to be able to cut all around the board I had to stay away from everything that holds from the side. and in 25 years of machining boards I learned not to hold the stringer. a) they are not vertical and b) they are not straight. if you hold the stringer you can not compensate for that error which in most blanks puts you at least 1/8 out.

it is easy to understand that with all the restrictions not much holding can be done, ergo the cutting must be efficient and avoid friction. my cutter hits the foam about 100km/h faster than Schumacher hits the straight in Imola and before the blank knows what happens its all over. painless. there are many more details to look into like very hard stringers and different glues used, blank twist and so on but I solved all those problems and it was not always easy.

very important to me is the work environment and to get out of the dust I designed the machine so I can load the blank in the front, go in the controllroom next door and press the button. the blank disappears and is cut in the rear part of the machine where there is all the dust and noise. when finished the blank appears again, I pick it up and put the next one on. this makes the machine about 7 meters long but who cares.

there are some other important things I learned over time which I all implemented in my design. so, if you want to know if the parts you use can handle the environment take out all the seals and try. if it still works after a while you are right; if not you will have trouble as no seal will seal good enough. you can never get rid of the dust and you have to learn to make it your friend.

another key issue is the software and Jimmy and Ralph have done a fascinating job. the mathematics behind are way more complex than you would find them in a CAD package, its a totally different game all together. a computer novice can learn to design a board in hours and as the program also controls the setup of board and blank within the machine, it gives you total control of the result and makes the job very easy.

I also designed the machine in a way that enables me to future proof the design as I have still some little ideas up my sleeves which I want to develop and implement.

all this is controlled by oversized brushless servo motors as only they guarantee a smooth travel day in and day out. my speed under cutting for example is 12 x the maximum travel speed of a shopbot which may explain the price differnce. but please keep in mind that I designed it as the new age planer, the tool for the shaper as he has the knowledge and experience to get something useful out of this machine.

have fun

Dammit Miki,

You’re just making me more curious! If I take the trip to AUS, can I have alook at it if I sign all the papers? :slight_smile:

Anyway, it sounds like a bit of fresh thinking outside of the box. Good on ya.

regards,

Håvard

thanks for the compliment. and I honestly believe we kind of deserve it a bit. and yes, if you pay the AUS $ 10 000 deposit and sign the confidentiality paper you are welcome to play with “her”. you’d love her, I know. to make your mouth water a bit more, here a screenshot of the control center. this is where you place the board in a blank of your choice, determine the parameters and create the cutting file. but the program has many other features that help you design exactly what you want even down to the nitty gritty like 1:1 design assistance where all parts (bottomcurve, deckscurve, outline, rails at any position) can be designed using your old templates. so, don’t throw them away just yet.and the deck is a curve (surface), not a thickness profile; something of great importance.

thinking out of the box was part of it but also avoiding the influence from what is out there. and keep in mind, most people involved including the programmer are surfers, its only me who is a sailboarder and boogy boarder. sorry about that.

simlpicity is the key except for the program. the program is where the design is created and my mates did a job second to none. it is the second program I have been involved with so I could get Jimmy and Ralph on the right track from the beginning. and even I have a university degree in mathematics most of it is over my head. but it works and thats that.

another issue I would like to mention are the ghostshapers. ok, they lost their job but they knew it since quite a while. and they all had the program on their computers and the possibility to learn and adapt to the new ways. interesting in itself, the ghostshapers who stayed in the business come to me now as customers.

have fun, play hard.

aah, here a little throw in: I saw your inerest in the Salomon core. interesting stuff and who knows where it leads to. I like everything that keeps the popouts at bay. but there was a guy in switzerland in the late 70’s - early 80’s, in the nor-east, who made sailboards in a similar fashion. I am sure we all could learn a lot from him, the brand name was “KOYOTE” as far as I can remember…

is this the sort of thing you were talking about from switzerland miki

http://www.airinside.ch/tech/tech.html

Hey Miki, AUS $10000 is a bit steep for me, sorry…

I agree with you, the key to success with such a system is user friendly software. I write software for a living, so I could really appreciate the nuts and bolts that go into the software. Still, you need a machine that can accuratly reproduce your computerised design.

I wish I had the money to make a simple 3 axis stepper controlled gantry router, because even with it’s limitations it would be a heeluwalot closer tolerance than what I can do by hand. But then again I’m just a newbie hobby builder.

regards,

Håvard

ahhg shucks haavard, i was hoping you would be the eye in the sky, the european ambassador of this new shaping machine, flooding your continent with your shapes and keeping us all appriased of the machine’s foibles.

can’t get enough info out of the webpage but it very much looks like the evolution of the hollow sandwich blank. look more

all the cheap stepper motor setups will certainly give you the motion to shape a board but keep in mind that a blank is expensive and easily ruined.

on the other hand, if you keep her running slow it will keep the pressures off which increases your chances to succeed. never give up. you will find a soluten. its out there…

Miki,

Are shapers you deal with sitting down and designing boards from start to finish with your software or are they shaping by hand and getting the boards measured and “digitised” and then tweaking a few things on screen ie letting on the design process take place in the shaping room and using your set up as a shortcut to a finished board - just curious.

love your question. and the answer is 100% CAD. every shaper reaches the goal different but it never takes long as the program takes care of that. I personally hate laser scanning, it needs smoothing algorithms and it all ends up as one soup. within our program you can position guide points, the meassurements a shaper normally uses, for deckscurve, bottomcurve , outline and the slices. these points are often copied from datasheets, meassured boards, cut out stringers, chopped up boards, digitized with a laser scanner (I have one for sale, interested??) or out of the shapers head. then you bring the curves through the points, throw a blank in the machine and shape it. after the shaper has the first board in his hands he begins to understand and very soon the computer is in the shaping bay. the program offers many ways to assist the design and you also can load your magic board as a “ghost” and copy/replicate parts of it. at any position within the board you can create a slice and you can “walk through” your design. a few basic rules and techniques have to be learned but the process is quick. after I deliver the shaped blank the shapers check it in their shaping bay and make the changes they want on their computer. the program shows both, new and old, and after 2 or 3 go’s the shaper has the first of his designs exactly as he wants it. and I mean exactly. no humps and no bumps. from there things grow rapid. first some small changes, then different sizes and within a week full custom designs.

some of the more conservative shapers are sceptical about this “modern computer thing” and use me or Jim as the middleman. they say what they want different and I do the “hard work” on the computer. but this never lasts long. after a while they all want to know which laptop I recommend… you see, it could not be more 100% CAD

interesting, most of these CAD programs for designing boards have originated from boat hull design programs and have been modified for surfboard design. From my experience these have limited design perameters and never quite come out exactly as you design them on the screen. Atleast from my experience, mostly due to the CAD program computing and “creating a surface” though these cross grid pattern (hull).

Laser scanning has been obsolete for board designing here in the states for close to 10 years. I have found the most accurate way to digitize a board is using the probe method. Using this method will allow you to have much more control over your tool paths.

There are basically 2 techniques for digitizing methods of scanning with the probe method. The faster method is to scan grid patterns accross the stringer at graduating hull sections. Same type of cross section data acquisition as the boat hull method. I have found that this method is not nearly as accurate due to the computer averaging out the missing XYZ points to “create a surface”. The other method which I prefer is very time consuming but much more accurate to the master. Which is to scan the ENTIRE half of the desired side. (not the across the stringer “grid” method.)

Using this method you can actually control all your XYZ data and it will pick up 10’s of thousands of points from the scanned surface (where the cad method is an averaged out process that is computed by the cad processor), the actual essence of your hand shaped design is picked up with this probe techinque. I have had a few shapers mention that their milled boards have a much more of the hand shaped essence to them in comparison to the CAD designed or cross grid probe method. And also when scaling you maintain more of the true essence of the board due to the way the XYZ data acquisition. No wierd areas where the computor is “filling the void.”

The CAD design programs are fine if you just want to design a board. But the problem is you can spend hours and days refining your design on the computor and it may not work. You have spent all that time and the design has not been proven. Sure with enough time you may fine tune it. But it takes much longer from design to production.

Digitizing the entire surface method is much more accurate to a proven shape, also maintains the subtleties of hand shaping. Much of the CAD originated designs I have seen seem to have a similar “cookie cutter” plain Jane look. Hard to explain, but to a seasoned shaper it’s quite noticeable. Just my .02 cents.

oak, woulnt the probe method take a lot of time to correct all the wear/dents etc on the computer after? i know what you mean about the programs generally being made for boats etc, having tried the aps software i found it to be very surfboard designer oriented! im looking forward to having my first ones cut on the aps in a couple weeks when ive got thru all that i have on at my factory ay present