Congratulations On Your Purchase Of 
"DIY CNC Machine"

The overall size of the Smart Saw is: Width: 740mm (29 1/8"), Length: 1200mm (47 1/4"), Height: 1610mm (63 3/8")

The size of the cutting/carving area is: Width: 372mm (14 5/8"), Length: (385mm (15 3/16"), Height: 135mm (5 5/16").

Yes you can expand the dimensions of the Smart Saw as long as you follow the same building process. Keep in mind that doing this you will need to make measure adjustments in length to the mechanical parts like: threaded drive rod, precision linear rod, linear guide rails, to some metal parts like: rectangular tubes, etc.

The software which controls the machine is Mach 3. Mach3 works on most Windows PC's to control the motion of motors (stepper & servo) by processing G-Code.

G-code, which has many variants, is the common name for the most widely used numerical control (NC) programming language. It is used mainly in computer-aided manufacturing to control automated machine tools. G-code is sometimes called G programming language, not to be confused with LabVIEW's G programming language.

G-code is a language in which people tell computerized machine tools how to make something. The "how" is defined by instructions on where to move, how fast to move, and what path to follow. The most common situation is that, within a machine tool, a cutting tool is moved according to these instructions through a toolpath and cuts away material to leave only the finished work piece. The same concept also extends to noncutting tools such as forming or burnishing tools, photo plotting, additive methods such as 3D printing, and measuring instruments.

The G-Code is generated by your CAM Software. After you have finished your project into your CAD software, save it as .dxf file. Then insert the .dxf file in the CAM Software, and save the project as G-Code. We strongly recommend to use V-Carve Pro Software, because this is both CAD and CAM software.

Yes you can download all the materials, and also burn it into your own personal DVD, but keep i mind that all the materials and files are not to be sold/rent after this.

Yes the Smart Saw can carve very detail designs, like inner cuts and exterior cuts.

I used a Milwaukee DG-30 Straight Grinder, but you can use any router/spindle for your machine, but keep in mind that doing so you will need to make some adjustments.

Yes you can operate the Smart Saw Using Linux OS. Here is a link with more information: http://linuxcnc.org/

For sketching and creating your personal projects I recommend VCarve Pro with emc2 for Linux. Here is a link to a forum where you will find information about VCarve Pro with emc2 for Linux: http://www.cnczone.com/forums/vcarve-pro/37112-vcarve-emc2.html

Yes you can operate the Smart Saw using MAC OS. Here is a link with more information: http://blog.cnccookbook.com/2013/11/01/worlds-first-mac-os-x-cam-software-cnc-software-suite/

On the MAC OS you can use AutoCad, TurboCad, etc. for sketching and creating your own projects.

I have used a Nema 34 Stepper Motor, but for the size of the machine, nema23 can be used as replacement without any problems.

The tolerance of the work is: 0.6mm (1/32"), this is due to the frame being built from wood, if you aim for higher tolerance, you can replace the wood parts with steel and aluminum. We are working on a new version of the DIY Smart saw made of aluminum and will offer the video guides and plans for free to all existing clients, you will receive an e-mail from us when the plans are available in the download area.

After you receive all the materials, the building time is under 4 days if you never built a cnc before, if you know what you're doing, you can assemble this machine in 1, max 2 days. The electrical calibration part is not very complicated and should take under 1 hour to accomplish.

Yes, in fact I recommend to use a USB breakout board, the only reason we used parallel port was that some of the people prefer using an old computer just for driving the cnc machine, which stays connected all the time, but the BOB can be easily replaced with a more advanced one.

The smart saw is able to mill aluminum using the right end mills and feeding speeds. For more information on this topic, checkout the feed rate calculator found on this page : http://www.cnccookbook.com/Calculators/CNC-Feed-Rate-Calculator.html

The smart saw can easily cut through any sort of plastic, including plexiglas, again make sure you check the feed rate and spindle speed when testing new materials and end mills.http://www.cnccookbook.com/Calculators/CNC-Feed-Rate-Calculator.html

Yes the Smart Saw can carve through acrylic or polycarbonate.

It is UNF type thread.

The connection between the Stepper Motor and the Threaded Rod is made through an Flexible Plum Coupling Shaft. You will have to measure the shaft of the motor you picked for your cnc machine and ask the threaded rod provider to mill the rot at one end to match the couplings you chosen.

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I have developed a web application to visualize the parts easier http://www.diymagicmachine.com/download/app/index.html and here is a quick video on how to use the application.

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