Planning Project: OSIDIAS (SFF taken to the extreme)

[craigbru]

Hey guys! I though I'd take the time to repost the planning thread for my next project. It's been an ongoing thread at bit-tech for several months now, but I thought I'd get you guys in the loop. I apologize for the cheap copy and paste job I'm about to do. :D

I'm also going to repost with everything unedited. While some things may seem out of context, it's probably the best way to show the evolution of the project. So, I hope you enjoy it, and I appreciate any comments you might have!

Feb. 6

Hey guys, I'm throwing around ideas for another new case... I've been sketching up some ideas and wanted a little feedback. Keep in mind that what you are about to see, is unfinished, and missing some key details. However, I like the concept, but I want your opinions on how it all fits together.

Okay, here is the core of the case. It's SFF of course, and it's damn tiny due to efficient space usage. I'm planning a DFI X58, SLI, full size PSU, 4 full size hard drives, pico, and watercooled CPU in this little package. Due to it's design, it should also run fairly cool. As of now, I don't plan on deviating much from this except for details like adding mesh, or possibly windows.

http://losias.net/projects/duality/pictures/Concept%201.jpg

I was then inspired by a RED camera cage I saw, and wanted to add a more industrial and sci-fi look to the case. The following is what I came up with. Of course it's subject to revision, but wasn't sure how it all fit together.

http://losias.net/projects/duality/pictures/Concept%202%20pers.jpg

http://losias.net/projects/duality/pictures/Concept%202%20left.jpg

http://losias.net/projects/duality/pictures/Concept%202%20front.jpg

Opinions?

Feb. 8

I've been playing around... what do you think of holes? Or maybe some variation of this?

http://losias.net/projects/duality/pictures/Concept%201.1.jpg

Okay, one more here. I added vents to the side panels. What do you think... too many holes? They will have mesh behind them, with the exception of the most forward hole, that will have a window...

http://losias.net/projects/duality/pictures/Concept%201.2.jpg

Feb.10

Well, I didn't have as much time as I had hoped for last night, but I did make a few small revisions. I made the side window slightly smaller, and added another opening beside it. Even thought the window is still larger than the rest of the openings, the spacing between them is consistent. Also, I added matching holes the the 'cage'. I'm unsure about the abundance of holes now, but I need the airflow. There will also be mesh behind them, so they won't stand out as much as the vents, for example. Speaking of mesh, I created some mesh with 1mm holes... Lol, talk about a CPU killer! I'll have to revise that... :D

http://losias.net/projects/duality/pictures/Concept%201.3.jpg

Now, this next part is just for Xtra. He wanted to see the interior arrangement....

http://losias.net/projects/duality/pictures/Concept%201.3%20inside%204.jpg

http://losias.net/projects/duality/pictures/Concept%201.3%20inside%202.jpg

http://losias.net/projects/duality/pictures/Concept%201.3%20inside%203.jpg

http://losias.net/projects/duality/pictures/Concept%201.3%20inside%201.jpg

Feb. 14

...and we have a name for this project... It will be OSIDIAS, and I've got to give my wife credit for coming up it. It's sad how much I concentrated on this trivial little detail, but I was convinced that I wanted something completely original. I think I've found it.

Over the last few days I've been making up a parts list. It's amazing how much aluminum will find it's way in to this box. I'm planning on making the outer shell out of a single piece of aluminum. I'll cut all the holes, then bend accordingly. Should be fun, huh? Also, as mentioned earlier, I'm going to braze all the parts together. This will free up any concerns about fastening parts together, and will guarantee a rock solid case. I also like the idea of no exposed fasteners anywhere on the case. This will be a new technique for me, and one that is rarely used in modding in general. I'm sure it's been done, but I can't name a project that incorporates it.

Feb. 16

I managed to get the interior tray about 90% finished over the weekend. Here is a pic of what I've got so far. Most of it will be bent out of a single piece, and the rest will be brazed together.

http://losias.net/projects/duality/pictures/Concept%201.4%20tray.jpg

Another updated pic...

http://losias.net/projects/duality/pictures/Concept%201.5%20iso.jpg

[craigbru]

Feb. 20

Okay guys, I've been playing around with renders. Since I'm using ViaCAD, Kerkythea isn't as easy to use as with Sketchup. I've basically got to export a .dxf, and then import it into SketchUp. However, when I do, not everything gets exported. I'm not sure how to fix that yet, but I'll keep playing around with it. So, the render below is missing a few components...

http://losias.net/projects/osidias/pictures/OSIDIAS%20render%201.jpg

Feb. 28

Okay, I've got a small update here. I've added the LCD to the front, and an Aquaero to the right side. There's also a new reservoir on the rear, but I've got to finish a little tube routing before you see that.

http://losias.net/projects/osidias/pictures/Concept%201.5.2.jpg

http://losias.net/projects/osidias/pictures/Concept%201.5.1.jpg

I probably should have added a few comments. The LCD is capable of rotation and swiveling. Left, right, up down, and portrait/landscape.

One more thing... I've started to order a few parts... :D

One more small update here. I've finished the interior tubing layout. Simple and efficient...

http://losias.net/projects/osidias/pictures/Concept%201.5%20water.jpg

Mar. 3

I've got about 90% of the details finished on this case. I'm still tweaking though. Last night I managed to make a little more room for larger fans. Originally I was only planning on 25mm thick fans, now I've got room for my monster San Ace 1011's. This thing might have enough thrust to fly. I've also got to do a little more interior parts placement. The Pico-ITx was originally located on the lower right rear, but I've since added the Aquaero to that location. That means I need to find a new spot for the Pico. I'm also looking for room for a Multiswitch, and USB hubs. I'm also thinking of adding a single SSD to the system for my OS. That would make for a total 5 drives. A SSD for the OS, a pair of Velociraptors in raid 0 for games, a 750gb drive for data and backups, and another 750gb drive for the Pico.

Mar. 5

I've got a quickie ViaCAD render here. No time for anything prettier, but I thought I'd show you the color scheme I'm likely going to use. Although my Duality project may be postponed, I loved the colors enough to use them here. Before settling on the orange, I ran through a rainbow of choices, and came back to this. It just stands out. :thumb:

http://losias.net/projects/osidias/pictures/Concept%201.5%20spot%20render.jpg

Just a slightly better render...

http://losias.net/projects/osidias/pictures/render2.jpg

Mar. 23

Okay, I'm sure you guys are tired of seeing all the lame render pictures in this thread... I assure you, these are different though. Dark~3nergy has put his talents to use for me, and created the following...

http://losias.net/projects/osidias/pictures/1.jpg

http://losias.net/projects/osidias/pictures/2.jpg

http://losias.net/projects/osidias/pictures/3.jpg

Many thanks go out to D~3 for all his time!

Okay, thanks in part to partial inspiration from this (http://forums.bit-tech.net/showthread.php?t=164178) thread, I came up with an idea I'm going to expand on. I've long thought about having fun with transparent LCD's, but redders' thread made me consider it all over again. So, it was time for a little experiment. The following is a standard 7" LCD removed from it's housing, and with all backing and polarizing film removed. What we have here, is what I intend to use as the side panel windows on OSIDIAS. For lack of a better term, I'll call them active windows. You can see that as long as there is a light source behind the LCD, dark objects and text is shown through. Granted, colors would be washed out, but the concept is still sound...

http://losias.net/projects/osidias/pictures/project-hutch1-007.jpg

http://losias.net/projects/osidias/pictures/project-hutch1-006.jpg

This could be fun!

Apr. 22

It's been awhile since I've posted an update. So, I figured I'd get you all up to speed on how I've been spending my time. Project: Hutch will be getting some long overdue attention soon, but in the meantime, I've got some new hardware to play with. Although I've not started an official log, there have been some parts arrivals for Project OSIDIAS.

I've got an Asus Rampage GENE II, Intel i7 920, 6GB OCZ Platinum, and a SilverStone DA1000 PSU freshly delivered. I'll be pairing the new parts with my existing EVGA GTX 260's. There may be a video card switch in the near future, but I'm using what I already have for the moment. Also arriving shortly, will be a slot load Blu-ray drive. All the above parts will be the heart of OSIDIAS, and I'll have a running system long before the project is actually finished.

So, how about a few hardware pics?

http://losias.net/projects/osidias/pictures/p3270006.jpg

http://losias.net/projects/osidias/pictures/p3270007.jpg

http://losias.net/projects/osidias/pictures/p3270008.jpg

http://losias.net/projects/osidias/pictures/p3270009

http://losias.net/projects/osidias/pictures/p3270010.jpg

http://losias.net/projects/osidias/pictures/p3280011.jpg

As of now, I've got most of my software and games installed. Although I've only been using the hardware a short while, I can tell you this... It's the best hardware combination I've ever used. Everything is rock-solid, and I've not had a single error or glitch in two weeks of a fresh Vista 64 install. I'm really looking forward to getting the CPU on water and hitting the overclocks. Stay tuned!

May 11

Just a non-update update here... In between all of other miscellaneous projects (including current, but not log-updated Project: Hutch), I've been giving OSIDIAS's design a slight tweaking. One of the benefits of delaying the start of a project, is that it allows new and alternative ideas to come out. Ideas that may not have been possible if work was already underway. One of the things I realized, is that I may need to find away to attach all the ribs to the interior of the case. They will need to slide out with the motherboard tray. This will require them to be mounted to easily removable frames of their own. It's not really a big deal, but will require some interior redesign. I've also found the need to widen the case itself by a single centimeter. That change alone allowed for the following...

The biggest idea came to me as a sat at my desk listening to the whine of the fan on the Via pico-itx board in the Rogue. I've got no way to quantify it, but it seems lightly louder than before. So, I've decided to 'Langer-ize" it. In Jesse's outstanding Prometheus (http://www.realredraider.com/vbulletin/showthread.php?t=446) log, I suggested the possible use of a Cooler Master Aquagate Viva for watercooling the pico. Well, I'm now taking my own advice. I've found room for a secondary watercooling loop... Utilizing the Viva's pump and radiator, as well as some very creative parts placement, will allow me to ramp the insanity up another notch. Stay tuned for updated sketches...

[craigbru]

I've been pretty busy lately, but I thought I'd show you one of my interior revisions. I've changed the internal supports to something a little stronger, and changed the layout slightly. In addition, the case is now able to fit most any rad up to 56mm in depth. Also, I've made room for the second radiator (Aquagate) for cooling the Pico, a 3rd fan over the video cards, and finally room for my Wintsch Labs peltier block. I've got to draw the block in CAD yet, but it should fit. Once I get that done I can get the tube routing planned out. More to come!

http://losias.net/projects/osidias/pictures/concept-17.jpg

[craigbru]

Well, that pretty much get everything up to speed here. If you've got any questions about the blanks, post up, and I'll answer them.

Although I had planned on making the case out of aluminum, I'm now looking in to carbon fiber instead... This should prove interesting... :D

[AntraxLife]

begin a worklog forum thread! :D i love the design, it looks really nice with the orange :D
just awsome ill give you Rep for this design, ill give Dark~3nergy some rep to for his amazing skills :D your gonna earn it man! awsome start keep it up. :)

-AntraxLife

[craigbru]

Haha, thanks man! I'll start a worklog once I actually begin construction. I've got another project to finish up first, and then I'll start on this in a month or so.

[craigbru]

I just can't stop revising... I was looking at the newly added 70mm radiator, and I got to thinking... It's just not big enough. Granted it's plenty for the Pico, but what if I ditch the idea of watercooling it, and add another radiator to the main system? Well, with a few small revisions, I now have room for a X-Flow 240. Why the X-Flow? I'll need to relocate the G1/4 fittings, and this rad would allow the most workable solution. I won't be able to fit 120mm fans on the second radiator, but I'll make sure it does get some air. Details are to be worked out on that yet...

http://losias.net/projects/osidias/pictures/concept-18.jpg

[AntraxLife]

cool, you migth just hold on to the 70mm fan idea, it'll proberly work out just fine, hope to see you getting started soon :D just want to see this beauty being built in all it's glory :up:

-AntraxLife

[craigbru]

Thanks mate! I'm still playing with parts placement, but I'm finding myself getting very limited now. The great part about using 3D CAD is that it's dead simple to drag things around. I sure wish I had taken this approach with my Rogue project...

[craigbru]

Here is what I'm planning on using for the case itself. You can't go wrong with carbon fiber, right?

http://losias.net/projects/osidias/pictures/carbon-fiber-fabric-cloth-2x2-twill.jpg

http://losias.net/projects/osidias/pictures/orange-carbon-fiber-kevlar-fabric.jpg

Since the case will be formed out of a single piece of material, I'll be experimenting with some reverse molding and vacuum bagging techniques. It's either going to be the coolest thing ever, or a colossal failure. I can't wait!

[AntraxLife]

haha nice, is that orange carbon you just buy in the store or is that costum home painted carbon, because it look's amazing :D
hope you can use both of em! :D send me a pm when you start working on this one, i wanna sub+ :D

-AntraxLife

[craigbru]

It will be actual carbon fiber cloth that I'll mold. It should look pretty good!

I'll let you know when I start. I'm about a month away.

[AntraxLife]

cool, im currently working my butt off just to get the money for my new gaming rig, maybe you can hlep me find where i can post rig specs and photo''s?

ill be waiting for the mod :D

-AntraxLife

[Kayin]

One of us can't go anywhere without the other showing up.

MAN this keeps getting better, and I can't wait to see what you can do with bagging that CF. Talk to Jesse about that yet?

I can lay fiberglass as well as the next guy, but CF is still beyond me.

That reminds me, I need to get to work on a secret project...

[craigbru]

True Kayin, the net's a small place, huh?

I haven't talked to Jesse specifically about the bagging, although we've talked CF before. I've also done a fair amount of research in to what I'm trying to accomplish here. I'll never be completely prepared, but I'm always willing to give it a shot, and learn along the way. It's always worked out for me so far.

Secret project?

[chaksq]

I really like this concept, looking forward to the actual build.

[craigbru]

I really like this concept, looking forward to the actual build.

Thanks man!

[rendermandan]

Looks like a pretty cool project. Good luck working with the CF.

[craigbru]

Looks like a pretty cool project. Good luck working with the CF.

Thank you! The carbon fiber will be a fun challenge. I really have to give you credit for some of the inspiration. :D

[AntraxLife]

hehe, youre really looking forward to doing it aint ya? :D
well, youre not the only one then. :up:
btw you got a price tag on the carbon fibre?

-AnthraxLife

[b4i7]

dude... you havent even started building this and i already want it

absolutely amazing design.... youve got my gears turning for a portable for DJing

[Zephik]

Holy ****! How did I miss this one? How freaking awesome looking. This definitely needs to be built! or sold to a company that won't fudge it up so I can buy one. lol

Even if you don't build it, you have some very sexy designs on your hands, so I do hope you go through with it! Very impressive in any case.

[Eclecticos]

Wow! This is Great. Really like the designs.
One impressive small form factor unit for sure. +Rep

[craigbru]

hehe, youre really looking forward to doing it aint ya? :D
well, youre not the only one then. :up:
btw you got a price tag on the carbon fibre?

-AnthraxLife

Without a doubt!

The CF isn't really that bad... it's around $40 per yard at 50" wide. Well, 'that bad' may be relative, but I though it would cost more. I'll likely only have around $200 worth of CF in the build. If I were to use large aluminum sheets at 2mm thick, it really would be that much cheaper.


dude... you havent even started building this and i already want it

absolutely amazing design.... youve got my gears turning for a portable for DJing

Haha, thanks man!


Holy ****! How did I miss this one? How freaking awesome looking. This definitely needs to be built! or sold to a company that won't fudge it up so I can buy one. lol

Even if you don't build it, you have some very sexy designs on your hands, so I do hope you go through with it! Very impressive in any case.

It will most definitely be built. I've accumulated a majority of the parts already. In fact, I'm ready to go once I finish up another current project.


Wow! This is Great. Really like the designs.
One impressive small form factor unit for sure. +Rep

Thanks! I really tried for something unique and different this time around. In fact, I'm even contemplating a matching NAS box to go with it... :)

[craigbru]

As the beginning of this project gets closer, I've been receiving a steady stream of parts and materials. Of those parts and materials, the carbon fiber is probably the most integral. With it, I'm hoping to take what I hope is a pretty cool concept to begin with, and take it to the next level. While there are many cases made of aluminum or even wood, a case constructed of carbon fiber is a much rarer occurrence. Fellow modders Langer, MKmods, jhanlon303, and rendermandan, have all worked with it in some capacity, and I owe them credit for inspiring me to use it here as well. With that in mind, I went ahead and ordered an orange carbon fiber/kevlar blend. This particular fiber will be used for the side panels and ribs on OSIDIAS.

So, without further delay...

http://losias.net/projects/osidias/pictures/p8220128.jpg

And one more pic...

http://losias.net/projects/osidias/pictures/p8220126.jpg

More to come!

[taintedplay]

that carbon fiber looks amazing!

[AntraxLife]

wauw.... :D the price is great for CF altho the price tag overall i woulndt pay till i got it :P can you send me a pm when you start building this B-E-A-uty :D
wouldnt want to miss it for gold!

[craigbru]

that carbon fiber looks amazing!

Thanks man!


wauw.... :D the price is great for CF altho the price tag overall i woulndt pay till i got it :P can you send me a pm when you start building this B-E-A-uty :D
wouldnt want to miss it for gold!

Thank you! Sure, I can PM you. Expect it to start in a month or so.

[craigbru]

Now, this is completely off-topic, but how many of you have visited my site lately? Not only is it always updated first, but I posted about an upcoming experiment... I'm getting set up to do live streaming from the workshop. I'm not entirely sure how successful it might be. Heck, it might even be a complete distraction. I thought it sounded like fun though. For now, I'll send out messages via my @craigbru twitter account when I stream. My plan is to be tested and tweaked in time for the beginning of this project. Stay tuned!

[craigbru]

Despite the lack of 'real' work done on this project, I've still been collecting a steady stream of parts. One of the most anticipated of these parts arrived in a box from Aqua Computer (http://aquacomputer.de/) in Germany. Inside was the electronic heart of OSIDIAS. These parts will be responsible for monitoring almost every electrical aspect of the case. From fan speeds, to temp monitoring, to lighting, and even powering up and down. Although I've got much detailed planning to do to make this all happen, I'm looking forward to the challenge.

So, what did I get? Here are all the parts laid out for inspection.

http://losias.net/projects/osidias/pictures/P9160323.JPG

One of the most critical parts, is this Multiswitch. It is controlled via USB through the Aquasuite software. This will be the electrical switching station for anything having on/off requirements. The lighting would be a good example of this.

http://losias.net/projects/osidias/pictures/P9160324

Next up is the new Aquacover for the DDC pump. All specs aside, it was just too damn good looking not to throw in the system.

http://losias.net/projects/osidias/pictures/P9160325.JPG

Now we have the new flow sensor and inline temperature sensor. Both of these parts are very high flow, and low restriction.

http://losias.net/projects/osidias/pictures/P9160326.JPG

And finally, we have a VFD Aquaero. This is really the brains of the operation. Everything starts here. All monitoring and control runs through here and the Aquasuite software via USB. The Aquaero will be linked to the secondary Via pico-itx system, and a touchscreen LCD. These components working together will allow seamless and automated system control and monitoring.

http://losias.net/projects/osidias/pictures/P9160327.JPG

One last thing worth mentioning, is the Powerbooster modification made to the Aquaero. This addition is a special cooling block and a small hardware modification of the Aquaero which will allow you to use a Laing pump on fan channel 1. The other three channels will be able to handle 15W instead of 10W. This increases the available overall power to 45W. It's more than enough in my case.

http://losias.net/projects/osidias/pictures/P9160328.JPG

Now, to go play with some hardware...

[x88x]

Oooh, shiny. I like where this is going with the computer-controlled...computer.. lol Seriously though; this is looking pretty awesome.

[jdbnsn]

Beautiful concept Craig! You are the SFF mack-daddy!!!

[craigbru]

Oooh, shiny. I like where this is going with the computer-controlled...computer.. lol Seriously though; this is looking pretty awesome.

Thanks man! I appreciate it!


Beautiful concept Craig! You are the SFF mack-daddy!!!

The SFF mack-daddy, huh? Lol, that's a new one! Thanks!

[rithunder916]

Lookin good! when do you start building.......

[craigbru]

Lookin good! when do you start building.......


Thanks! I'll be starting this as soon as I finish Project: Hutch. I think I said I would start it in a month or so, about 4 months ago... Lol, I really will start it soon though. I've got most of the parts, and now it just comes down to time.

[craigbru]

Oh hell, did I really say this project was a month off... Um, nevermind to that...

There's a funny thing that happens when you are planning a project way longer than you had anticipated. Changes. Changes happen. Many changes actually. Although I've stood by the basic form factor I had first envisioned, things have been in a constantly evolving state. A tweak here, a tweak there, in the ongoing pursuit of perfection. Every last detail is being planned and thought out in advance. Just when I think I've got it nailed, another idea pops in to my head, and I'm revising again. Now, I can't keep this up forever, and I'll soon have to commit to a design plan, but until that happens I'm going to have a little fun.

So why the rambling intro? Well, I've got another idea. This one is slightly more costly, slightly more unique, and way more insane. In fact, this sort of thing wouldn't even have been very economically feasible even a year or two ago. What sort of thing am I referring to? UMPC's... Yes, why stop at 2 systems in a single machine, when you can have 3. Do I have your attention now?

Here's what I'm thinking... As OSIDIAS stands right now, I've already got a 7" touchscreen on the front. This screen was to act as the control interface for the pico-itx system, which in turn monitors and controls almost every aspect of the main system. If I replace that touchscreen with a UMPC linked via a wireless connection to the pico, I can retain the same functionality through software. The biggest advantage then, is the ability to remove the UMPC and control the system remotely. On top of that, I've got still got all the original functions of the UMPC itself. Overkill? Nah, there's no such thing! So, stay tuned for updates as the plan gets revised and implemented. Insanity has reached a new level...

I suppose you want to see the UMPC I plan on using, huh? :D

http://losias.net/imagehost/images/34251004s01s.jpg

http://www.myviliv.com/eng/product/x70ex.asp

[Kayin]

I would say I hate you, but I can confidently say that when I'm completed with my next project, nothing here will touch it for speed.

I mean we're playing in different time zones.

I wanna see how you do this. I could use a screen for my next big one, but the cash has to go to all the stuff it takes to get it running.

[x88x]

Hahaha, awesome idea. I can't wait to see how you incorporate it. Are you gonna mod the UMPC's case too?

[Mach]

I'm intrigued by your ideas and would like to subscribe to your newsletter:think:

I love the idea. It'll effectively be all the systems that anyone needs in one SFF package; crazy performance, storage, mobility, and control. Any thoughts about interfacing it with your house for home entertainment served off of the base unit? Watching for the magic to begin :)

[craigbru]

I would say I hate you, but I can confidently say that when I'm completed with my next project, nothing here will touch it for speed.

I mean we're playing in different time zones.

I wanna see how you do this. I could use a screen for my next big one, but the cash has to go to all the stuff it takes to get it running.

Lol, thanks Kayin. I tried for speed in my last build, and got stuck with a crap MSI board that wouldn't OC worth a damn. Sure, my CPU temp was sitting around -25C, but it was wasted energy with no OC. So, I decided to take a different route this time around. Maybe this one will even be easily upgradable for a change. :D

The details on how this will play out are still somewhat vague. It's going to come down to the best software for the job. I'll be getting the UMPC sometime in the next 2 weeks, but since I haven't started any construction yet, I've got some time to play.


Hahaha, awesome idea. I can't wait to see how you incorporate it. Are you gonna mod the UMPC's case too?

Thanks mate! Physically mounting it shouldn't be an issue, as I mentioned, all the tricky stuff will be in the software. As of now, I don't have plans to mod the UMPC case. I'll look it over once it arrives.

[craigbru]

I'm intrigued by your ideas and would like to subscribe to your newsletter:think:

I love the idea. It'll effectively be all the systems that anyone needs in one SFF package; crazy performance, storage, mobility, and control. Any thoughts about interfacing it with your house for home entertainment served off of the base unit? Watching for the magic to begin :)

Lol, I think my wife would kill me if I took the time to write a newsletter...

I've got lots of thoughts about this being an entertainment hub. In fact, that's part of the functionality the UMPC will bring in to the mix. Since it is wireless, I can control the PC from anywhere. All I would need is simple PC wherever my TV is located, and stream to it.

[x88x]

EDIT:
Sorry, my browser got confused and sent the same thing again.

[craigbru]

No worries... I thought I was having deja vu for a moment there...

[Kayin]

Well, I can understand your issues after being unable to OC...

I'm burning up my rig trying some of what I'm trying (Sketchup+multiboxing) so I'm going with this setup to try to finally build myself a true monster.

You, however, seriously have my interest piqued. So are you discarding your original touchpanel for that?

[craigbru]

Yes, I've convinced myself that a little OC is good enough... I'm running at 4Ghz on my i7 :D Anymore really isn't needed for what I do. If anything I need more memory yet...

Yes, the original touchscreen will be replaced by the UMPC in the same location. The Viliv happens to be the perfect fit. I'll find another mod to work the original touchscreen in to.

[craigbru]

I really need to make an update here! The Viliv has arrived, and I'll be doing a video review of it shortly. In the meantime, I've been playing with other ideas. You see, with the addition of the UMPC for system monitoring, I needed a reliable way to relay information to it. I have been toying with bluetooth, but have a 2 device limit on networking them. So, wi-fi was the next obvious choice. That brought it's own set of issues. The pico must always be on and networked, the main system may not always be, and the Viliv must also always be networked. I also want to ensure the Viliv and pico always have internet access. Not that big of a deal, right? Well, Samurize needs static IP's for relaying information, and while that is great for home use, what about when I go to a LAN? The IP's are subject to change, and that would throw everything off.

So, what's the fix? How do I get static IP's? The easiest way is to use an access point, in this case, a wireless one. Everything is wireless capable anyway, so I can assign each adapter it's own IP, and they won't change regardless of where the system goes. That's where this comes in to play... It's the smallest AP available.

http://losias.net/imagehost/images/p500.jpg

Okay, with that out of the way, I have 3 devices inside of OSIDIAS that need ethernet connections. The main system, the pico, and the access point. That leaves the need for a switch. This unit from Bytecc is the absolute smallest I could find. Everything must be internal!

http://losias.net/imagehost/images/topmicrousa20858933.jpg

Believe it or not, I've found room for both of those components inside the case without inhibiting airflow... When I get a chance I'll get some updated pics posted. Stay tuned!

[craigbru]

I had a little time over the weekend, so I thought I'd make something special for everyone that has been following this project. This is a video walkthrough of OSIDIAS. It explains how some of the components fit together, and I cover some of the design basics. Although I've left out a few details, I think you'll understand the project a little better. Enjoy!

http://www.vimeo.com/8832516

[craigbru]

Well, disturbed13 at bit-tech managed to pry an upcoming sponsor out of me...

So, since the surprise is out there, I might as well make the official announcement. I've been speaking with Ron Rogers of Romaxx CNC (http://www.romaxxcnc.com/main.html), and he's been generous enough to sponsor a HS-1 machine ready to run. I'll be using the machine on this project, as well as any future projects where applicable.

http://losias.net/imagehost/images/romaxx009600x581.jpg

The HS-1 is a very solid tabletop CNC, and will be able to handle most any job I throw at it. I wanted to work with Romaxx for several different reasons. The first of which is the standards by which their machines are built. There's no doubt they are solid. The second is the support Romaxx offers after the sale. They stand by their machines, and are quick to take care of any issues should they arrive. Lastly, there is a pretty good community of users on the Romaxx forums (http://romaxxcnc.proboards59.com/) that are willing to help and share their experience. All of these things added up to make it an easy decision for me.

I'll keep everyone updated on the machine's arrival, and I'll certainly post pics as soon as I can!

[OvRiDe]

Wow.. I can't wait to see that baby in action!

I know all the planning is going to pay off in the end, but I want to see if now! :D

[Oneslowz28]

Damn thats nice. Congrats man!!!

[craigbru]

Wow.. I can't wait to see that baby in action!

I know all the planning is going to pay off in the end, but I want to see if now! :D

Yeah, me either. I haven't worked with CNC since I was in high school, and that's been quite a while ago. This thing is going to open up quite a few new possibilities for me.

The sad part is, I'm still making small revisions, but could technically start tomorrow if I wanted. I just need to finish a current project first!


Damn thats nice. Congrats man!!!

Thanks man!

[craigbru]

Are you guys ready for this?

Well, it's finally arrived! Thanks to Ron Rogers of Romaxx (http://www.romaxxcnc.com/) for making this possible. What you are about to see is the unboxing of a shiny new HS-1 (http://www.romaxxcnc.com/hsproduct.html) CNC router.

This machine is considered a tabletop CNC, and as such, doesn't take up a lot of space. Since I work primarily in small form factor, this will fit 99% of every need I have. Even though it's a compact design, this thing arrived to me in a 125 pound box. 105 pounds of that is the machine itself. If weight is any indicator of strength, then this thing is a beast.

So, shall we look at a few pics of this thing?

The box...

http://losias.net/projects/romaxx-cnc/p3160292.jpg

http://losias.net/projects/romaxx-cnc/p3160293.jpg

Let's crack this thing open. It's definitely well packed, and bolted through the bottom of the crate.

http://losias.net/projects/romaxx-cnc/p3160294.jpg

http://losias.net/projects/romaxx-cnc/p3160295.jpg

http://losias.net/projects/romaxx-cnc/p3160296.jpg

http://losias.net/projects/romaxx-cnc/p3160297.jpg

http://losias.net/projects/romaxx-cnc/p3160298.jpg

http://losias.net/projects/romaxx-cnc/p3160299.jpg

http://losias.net/projects/romaxx-cnc/p3160300.jpg

http://losias.net/projects/romaxx-cnc/p3160301.jpg

That's it for now, but I'll follow up once the machine is setup in the shop. Until then!

[x88x]

Mmmmm, preeetty. :D Can't wait to see it in action.

Also, I love the giant emergency shutoff switch. :P

[craigbru]

Mmmmm, preeetty. :D Can't wait to see it in action.

Also, I love the giant emergency shutoff switch. :P

Thanks man! I'm still waiting on the end mills to arrive, and I've got to get the software sorted out. I'm hoping for cuts in a week or so!

[craigbru]

While I know everyone is anxiously waiting to see the CNC running, I needed to take care of a few small details first. One of those details involved a custom misting solution for cutting aluminum. Why mist? Well, for the work I have to do it can be just as effective as flood, yet it's so much easier. I should say it's easier, only if you can find a workable and convenient way to implement it.

I have been doing some research into CNC misting techniques, and most of the options are geared towards commercial applications, and are quite expensive. I wasn't really willing to spend $300 on something I was convinced I could do myself. Since I'm a modder, it only made sense to mod a homebrew solution. Many hours were spent Googling anything that misted, before I came across the mention of using an airbrush as an option. I tried to find where someone had actually followed through using this method, and came up with nothing. So, I figured I might as well be the first. Even if I'm not, I'm hoping my methods and documentation will make it easier for others to find and implement themselves.

Now, before any fabrication could begin, I needed an airbrush and dedicated on-demand compressor. Amazon came through with this (http://www.amazon.com/gp/product/B001TO55PQ/ref=oss_product) nicely outfitted kit.

http://losias.net/projects/romaxx-cnc/p3250292.jpg

http://losias.net/projects/romaxx-cnc/p3250293.jpg

http://losias.net/projects/romaxx-cnc/p3250294.jpg

Okay, well, now that I've got the airbrush, I need to find a way to get it mounted to the Romaxx machine. Since the mister needs to follow the mill bits as they cut through the material, it was obvious that it needed to be attached to some location near the spindle. It just so happens that there were some unused spindle mounting locations that would be perfect. So, I just needed to come up with a workable bracket of some kind. Not only did the bracket have to hold the airbrush securely, but it couldn't interfere with any machine operation whatsoever. I needed full X, Y, and Z operation with no limits or restrictions. I broke out the cardboard and started experimenting. This got me in the ballpark...

http://losias.net/projects/romaxx-cnc/p3250295.jpg

Since I was satisfied I had a workable idea, I committed it to metal...

http://losias.net/projects/romaxx-cnc/p3250298.jpg

I love bending things, so the newly cut bracket received some attention.

http://losias.net/projects/romaxx-cnc/p3250300.jpg

With the cutting of a few well placed slots, and the help of some rubber o-rings, the brush and it's coolant reservoir were attached to the bracket. I used a simple mounting method for two reasons. Ease of maintenance, the ability to have flexible mount points should some unforeseen interference occur.

http://losias.net/projects/romaxx-cnc/p3300305.jpg

So, let's get this bracket mounted! You can see how cleanly it sits in it's location. It's also easily adjustable for height.

http://losias.net/projects/romaxx-cnc/p3300306.jpg

http://losias.net/projects/romaxx-cnc/p3300307.jpg

There is plenty of room for travel with no interference.

http://losias.net/projects/romaxx-cnc/p3300311.jpg

Now finally, here are a few pics of the machine as assembled and ready to run.

http://losias.net/projects/romaxx-cnc/p3300308.jpg

http://losias.net/projects/romaxx-cnc/p3300309.jpg

http://losias.net/projects/romaxx-cnc/p3300310.jpg

All that I've got left to do is make sure I'm set for live streaming, and I'm ready to cut. If I can find a good material hold down solution, I'll give it a go tonight. (Yes, I'll likely be getting the aluminum top w/ mounting holes soon.)

[x88x]

Nice job; it almost looks OEM. ;) I can't wait to see it in action.

[TheMainMan]

Wow, this thing looks like a lot of fun. Only question I have, and maybe I missed this in the pictures, is how will the airbrush trigger? Will it be always on, or setup so that it triggers when cutting? Love the bracket and can't wait to see what this will churn out!

[craigbru]

Nice job; it almost looks OEM. ;) I can't wait to see it in action.

Thanks mate! I just happened to have some gold anodized aluminum on hand. :D


Wow, this thing looks like a lot of fun. Only question I have, and maybe I missed this in the pictures, is how will the airbrush trigger? Will it be always on, or setup so that it triggers when cutting? Love the bracket and can't wait to see what this will churn out!

Thank you. The airbrush will be triggered on constantly. Since the pump is activated on demand, there is no need to trigger it separately. The pump will be turned on and off via the Mach3 software.

[diluzio91]

Not knowing alot about CNC, is the sprayer for cooling lube (like the pink fluid the huge machines use?) while cutting metal?

[craigbru]

Not knowing alot about CNC, is the sprayer for cooling lube (like the pink fluid the huge machines use?) while cutting metal?

It most machines that would be correct. However, I'll be using denatured alcohol in mine. It has great lubricating properties when cutting aluminum and evaporates quickly. It should be relatively mess free. :D

[craigbru]

Hey guys, I did a live streaming test tonight on a dry run. I was having mic issues that have since been fixed. I was also experimenting with a dual webcam setup just to test it's feasibility. I'm not sure what I'll do with a second cam, but as you see, it's certainly possible to use one.

http://www.livestream.com/losiastechnologies/video?clipId=pla_06b67ff8-9601-4a51-bfd2-6283ae9d8f69


(If you happen to get an irritating overlay on the bottom of the video, just pause and start again, and it should go away.)

[craigbru]

Okay guys, since I have a habit of never being satisfied... I made a few changes to my CNC router. After my dry run with the picture in picture webcams, I started thinking about how cool it would be to add one of the cameras near the spindle itself. I thought it could capture the mill bit working as I machined. Well, in order to make this happen, I went ahead and got a $10 camera from newegg, and set out to find it a home.

I knew I had to get it as close to the spindle as possible, yet there could be no interference in the machine operation or safety. This was a must. The machine comes first, and these little extras second. So, as I was poking around with the cam, one thing became clear. My new mister bracket wasn't going to cooperate. I could either ditch the idea of a camera, or redesign the bracket. Well, I chose to make a new bracket. It is greatly simplified over the other one, but required the flexible metal shaft from a donor lighter. This shaft was the key to making everything work, as only this, a piece aluminum angle were going to be used in the new design. After a short while, the new bracket was in place, and I could move on the mounting the camera. This was even easier. I just needed a small aluminum triangle and a rubber washer... I removed the camera's original mount, and attached the aluminum. I then bolted the bracket to a free hole behind the spindle, and I was in business. So, shall we get on to a few pics?

Here you can see an overall pic of the machine. The new mister bracket, and the webcam behind the spindle are visible.

http://losias.net/projects/romaxx-cnc/p4090304.jpg

A little closer...

http://losias.net/projects/romaxx-cnc/p4090305.jpg

http://losias.net/projects/romaxx-cnc/p4090306.jpg

A few more closeups...

http://losias.net/projects/romaxx-cnc/p4090307.jpg

http://losias.net/projects/romaxx-cnc/p4090308.jpg

http://losias.net/projects/romaxx-cnc/p4090309.jpg

http://losias.net/projects/romaxx-cnc/p4090310.jpg

As you can see, there are no clearance issues of any kind. The machine is still just as easy to maintain, and I don't foresee any issues. Now all I need to do is get something cut!

[x88x]

Aw, it's a shame about that old bracket...it was so pretty. :P

Pretty sweet idea with the camera though; I can't wait to see it in action. Hopefully the shards won't get blasted all over the lens...

[craigbru]

It was pretty wasn't it? Lol, I had to change it though, and the new one will work just as well.

I'm going to make little clear plastic loops to put over the camera lens. I can just swap them and throw away as needed. If it doesn't work as well as i had hoped, I'm only out about $15 for the camera.

[Mach]

Awww man, you are so going to make want a CNC router, aren't you? Looking good Craig!

[craigbru]

You know you want one! No, I take that back... you need one! You can justify it, right, right?? :D

[msmrx57]

Oh I WANT/need one, simply can't jutify it right now. So many things it would get used for around here.

[craigbru]

Oh believe me, I've come up with a whole list of things I think I need to make...

[craigbru]

I managed to make a few cuts today guys. I was having a z-axis plunge problem which you will see in the first video in particular. (I've got videos 2 and 4 linked below). Apparently it's an occasional problem with Mach 3. I did manage to get it sorted though, and got all my cutting done. Take a look!

http://www.livestream.com/losiastechnologies/video?clipId=pla_8804960c-6617-45ac-9489-a1e822fd22be

http://www.livestream.com/losiastechnologies/video?clipId=pla_0aaba4ad-01c2-422b-9d44-c4d584e05332

[x88x]

I was having a z-axis plunge problem
So is that what the kids are calling it these days... :P


Seriously though, pretty sweet. Glad to hear you got that worked out. Now you just need to make a mount for your vacuum hose. :D

[craigbru]

Thanks man. I'll get a hose mount figured out soon. Cuts that don't take long aren't so bad for holding the shop vac, but I don't want to follow the mill around for some of the bigger jobs. :)

[x88x]

I couldn't find it on their website, but a while back I got an adapter kit from Harbor Freight that hooks to a normal vacuum. Making/finding something similar might be useful so you don't have to route that big tube everywhere.
http://i428.photobucket.com/albums/qq3/x13931x/HPIM0617.jpg

[craigbru]

Now that's pretty interesting. Thanks for the pic. I'm not sure what I'm going to do yet, but I do know I'm not going to do a huge foot assembly like you see on a lot of machines.

[diluzio91]

WE WANT SOME ACTION SHOTS!!! lol..

[craigbru]

Lol, I do have two videos linked a few posts up. Granted the quality is lower than I would like, but at least you can see the machine moving. :D

[craigbru]

I came home from work today to find a nice sized box on my front porch. Inside was one of the last items I needed for setting up my Romaxx CNC machine. It was a VT6040 vacuum table that I had purchased from ebay seller dcad100. It measures 24.0”x16.5” x 0.8125", and was the perfect size for my machine. The vacuum table will allow me to hold parts in place without clamping. Should I need to clamp things anyway, there are M6 holes on the table that should easily allow this.

So, should we take a look at the table? Here it is as it arrived to me.

http://losias.net/projects/romaxx-cnc/p4230316.jpg

Opening the box revealed a very well packed table.

http://losias.net/projects/romaxx-cnc/p4230317.jpg

The table also came with a the necessary tubing for hooking up to a 2" vacuum line.

http://losias.net/projects/romaxx-cnc/p4230318.jpg

Also included was a solid rubber mat for blocking off unused holes during vacuuming, and a holed rubber mat that sits below parts that are being cut. The holed mat not only allows transfer of suction, but will help keep the end mill just above the aluminum table surface. These should be easily replaceable should the need arise.

http://losias.net/projects/romaxx-cnc/p4230319.jpg

The table looks to be of pretty good quality, and is well constructed.

http://losias.net/projects/romaxx-cnc/p4230320.jpg

Now finally, here is the table sitting on the machine. As you can see, it's the perfect size. All that's left is to get the vacuum lines hooked up, and it's ready for use. More coming soon!

http://losias.net/projects/romaxx-cnc/p4230322.jpg

[x88x]

Interesting. I wouldn't think that the pull from a normal shop vac would be strong enough to hold something down again the force of a router.

[craigbru]

Well, even though it might be enough, I won't be finding out. I've got a nice vacuum motor I'll be hooking up in the next few days.

[craigbru]

I had a little more time tonight, and was able to get the vacuum assembly finished. As of now, the vacuum table is completely ready to use. I am pretty happy with the way that things turned out. It's compact, easy to maintain, and fairly cost effective. Of course, none of that matters if the table doesn't perform as expected. Well, I'm happy to report that it performs even better than I had hoped. I know everyone is anxious to see how it turned out, so let me walk you through the rest of the setup process...

There are really only 3 major components needed in a vacuum table setup. The first is obviously the table itself which I covered in the last update. The second is the source of the vacuum itself. For this, I went to industrial parts supplier Grainger, and picked up a vacuum pump. I selected a two stage tangential unit capable of 97 CFM and 81.8 Hg vacuum. There were more powerful units available, but this one was an outstanding deal, and worth taking a chance. So, let's take a look at the pump...

http://losias.net/projects/romaxx-cnc/p4230323.jpg

Now, I should mention that although this is a vacuum pump, it's also a blower by it's inherent design. Unfortunately the only fitting for attaching a hose is on the blower end. That meant I had to get a little creative and epoxy a fitting over the vacuum hole. It was a simple fix, but just one more step I had to take before I could move forward.

http://losias.net/projects/romaxx-cnc/p4260315.jpg

Okay, now we've got two of the three major components out of the way. The third? Well, that should be easy. We've got to have tubing connecting the table and the vacuum pump. This shop vac hose kit offered the perfect solution.

http://losias.net/projects/romaxx-cnc/p4250312.jpg

http://losias.net/projects/romaxx-cnc/p4250313.jpg

As you can see the shop vac hose was a perfect match for the tubing adapter and splitter that came with the table.

http://losias.net/projects/romaxx-cnc/p4250314.jpg

Now all that was left was to route the tubing and hoses, mount the pump, and connect everything together. As you can see, the whole assembly is pretty clean and simple.

http://losias.net/projects/romaxx-cnc/p4260316.jpg

http://losias.net/projects/romaxx-cnc/p4260318.jpg

At this point I was pretty anxious to kick it on and do some testing. I'll try and get some video of that up in the next day or two, but as I mentioned above, I was very happy with the results. I could lay a block of wood in the center of the table, and with the pump running, it was surprisingly hard to move laterally. Keep in mind that this was without blocking off any of the other holes in the table. Doing so would increase the vacuum significantly. I'm pretty confident that as long as my feed speeds are appropriate, and my end mills are sharp, nothing is going to move while vacuum is applied. The only way to know for sure is to actually cut something, and I'll be doing that very soon!

[x88x]

Very nice. I can't wait to see it in action.

[billygoat333]

I wonder if you can use that vacuum table for vacuum molding plastic. :think:

[craigbru]

Very nice. I can't wait to see it in action.

Yeah, I'm really anxious now.


I wonder if you can use that vacuum table for vacuum molding plastic. :think:

Possibly. I'm not sure how much vacuum you would need, but the table is pretty capable.