3D Engraved Eagle

This was a project for our Computer Integrated Manufacturing class in high school. The only requirements we were given was that it had to be wood, and we had to use the CNC router. After a lot of brainstorming, my partner and I decided on an engraving in a log. This idea sparked from just looking in google images and seeing what other people had done. We wanted to make this intractable to help anyone else in the future who may want to do something similar.

The supplies we needed for this project were:

- CNC router and bits

- the log

- chainsaw (or other method of cutting)

- band saw

- Dremel

- stain, polyurethane coatings

- planer

- computer with VCarve or similar software

The first step to our project was to locate a log that we could use for this project.

To find a log we could use for our project we visited a local farm stand where we saw there was a pile of logs. After explaining what we needed the log for, they were more then willing to let us take whatever we needed for our project.

We found a log that was about a foot tall and about a 13 inch diameter. We then cut the log down into 3 pieces (each about 4 inches thick) using a chainsaw.

The next step to this project was to make a perfectly flat surface for the CNC router to work with. To do this, we first face milled the log down until it was flat, using an 1 1/8 inch flat end mill bit. For us, this took three passes on the router because the cut was a little crooked.

After being face milled, we ran the log through a router a couple of times on each side, just to ensure a smooth and flat surface.

This step was to find a file. For us, because of our limited time for the project, we found and purchased a file from Etsy. We found the file we like, and purchased it for about $4.

After purchasing the file we imported it into the software we used for the project, VCarve. This software is very user friendly, considering there is endless tutorials on YouTube if you ever run stuck.

The Etsy user the file was purchased from was StudioSTL3D.

After importing the file into VCarve, we had to create the tool paths. This consisted of 4 different steps; Pocket (clearing the area around the eagle), 3D roughing (carving the general shape of the eagle), Profile (Cleans up to edges with a smaller bit), and last was the 3D finish pass (carving out the eagle with a small and precise bit).

For the CNC routing we used a Laguna IQ CNC router.

As explained in the previous step, there were 4 different tool paths that the machine followed.

The total work time on the CNC router was just over 2 hours after adjusting tool speeds and number of passes. The first two steps (Pocket and Roughing) each took about a half hour using a 1/4 down cut end mill bit. The profile took about 2 minutes using the same 1/4 inch bit. The final pass used a 5.4 degree tapered ball nose bit and that step took just over an hour.

This was a step just for cleaning up burrs that were left on during the CNC process. For this we used a Dremel tool with a sanding bit on it, just to clean up edges and places the router was unable to reach.

For this, we used a propane torch and just passed over the eagle a few times, just to give a little char and color along the edges.

For coatings on the eagle, we used the Minwax brand Special Walnut colored stain and after the stain had dried over night we used an oil based polyurethane coating to seal the wood and give it a nice shine.

This is a key hole used for hanging on a wall. This used a 3/8 inch key hole bit on the CNC router.