Hi Tyson, (sorry longwinded response, typical me)
As SurfDing said you will need to convert your design files to an appropriate machine
language. Conversions from BoardCad to .dxf or G-code are possible, you may have
those available within your company, in fact I would be very surprised if they did not.
Once you find a robust CNC program at work, your job will be to find its’ “import” capabilites
to bring in your BCad file.
There are several Surfboard design programs out there and most of them are available
as two types. The first type is a design-only version, and the other is a design/CNC
version. The latter typically comes with a hefty price tag. There may be places out
there with relaxed-enough policies to do a conversion for you.
Sounds like your company mills wooden products??? If it is a large firm you may be
able to get one of the on-site machinists to make a cutter for you. If not, there
would certainly be a vendor that visits your shop and they would give you the best
price on a custom cutting head.
Custom cutters we use on foam look nothing like the ones for wood. Ours look like a
small “top” with tungsten-carbide spikes all over it- no blades. The bits your company
uses are most likely bladed ones, and it would not be hard to modify an existing bit
to cut a board. My recommendation would be to use a straight-flute bit, 3"+ long
cutting length, 3/4" diameter. The end could be modified to cut as well. If this is
possible I suggest rounded end of about 4" to 5" radius with another radius transitioning
the end to the straight part, about 1/4" radius. If you have a shop foreman, they can
sharpen/modify bits for you. (BTW, our bits are spendy, you’re looking at $600 each
with a minimum order of 4)
If you will be machining with more the 3 axes, then the design of the cutter will be different
most likely egg-shaped or a sphere.
With all that said, I collaborated with an Aussie shaper/designer who had success using
a large twist drill, with the end ground to shape.
Keep pursuing this, you will learn a lot, which is a positive thing. It is too bad there are
still shapers out there who do not realize just how good milled designs have become.
I have been hand-shaping for 30+ years, no “rookie” who jumped onto a machine, and
I see the newest generation of shaping machines as “intelligent planers” in which I express
my “direct will” into the blank. I cannot find the words to describe how the designing of
boards has changed because of it. What I mean is, I can take a board that I’ve designed
and built from, change ONE thing, like rail tuck and run that board and test it. Been doing
this for 5 years steadily. And as Jim says, we’re pretty much tooled-up for “Onesy, Twosey”
style, as is most of our production. We primarily do custom shapes and we’ve never scanned
a board, (we don’t have a scanner) only designed virtually (there is a huge difference in file
quality with that alone) We now have many “magic” boards on file, created this way, and
have re-created them with much success. We also know what visual cues to look for in
the 3-dimensional design mode (wire mesh model) to get curves aesthetically right and pleasing
to the mind.
I hand shaped just a couple of weeks ago to salvage a blank that could not be fixtured in our
machine, I must admit, it was fun, and “I still got it” ha ha! Almost as much fun as designing on
my laptop! Heck I wouldn’t mind shaping a piece of wood with a seashell, if the conditions called
for it!!! ha! I got pretty close to what the machine would do, but the age-old dilemma was still
there, I had to spend over an hour of muscle work, sweating it, just to get to the “rough” state,
then that last half hour where I need to be accurate after getting beat up. OUCH! In the old days,
I would alternate, roughing the next days’ batch after finishing the previous days’ batch. Now I
realize the “beatings” are not necessary and I can focus on projecting my will into the foam for
an exact result.
Let me tell you, as a man of experience in both hand and machine shaping, the potential that’s
always been there for CAD surf designs is beginning to really be utilized. I am seeing first-hand
the process of developing a design to levels of detail I could never have imagined just a few
years ago… …and the results are showing where it counts, in the water.
If you are lucky enough to do several boards, you may begin to get a feel for the PROCESS
of designing for milling, and evolving a design with unprecedented accuracy, it’s great!
Best of Luck!
George