Carlson Design PTi-108" Plotter/Cutter

We don’t usually start our posts with a picture, but this is worth a least a thousand words!  One in particular — “Wow”.

In November 2012, we automated Oldcastle BE’s lamination cutting at their glass plant in Los Angeles, CA.  Oldcastle is the world’s largest building materials company and their Glass building envelop (BE) has the largest US national footprint with over 50 locations.  The Los Angeles plant is one of their largest facilities with over 250,000 sqft of IG, Tempering, and glass lamination

Lamination is the process where two pieces of glass are joined with plastic films to produce a stronger sandwich that is harder to break and safer when broken. Lamination rooms are climate-controlled clean rooms used to store film and make clean layups prior to entering a special oven. The cutter is used to quickly and efficiently cut the interlayer film on demand to fit.

The lamination room, where we spent most of our time, is impressive.  It’s clean, well run, and HUGE — the room is ~60′x~60′ and held at a constant 60 degrees F.  It’s big because they handle big glass, and large volumes.  On any given day they will cut 2000-4000 sqft of PVB and SGP.

Panorama of cutter and room. Remember our table is 9'x12'.

This means, material savings make a big difference.  Todd Neufeld, the pant manager, said, “Automating was a ‘no-brainer’ for material savings alone.”  Just like automated glass cutting and nesting, automating nesting and cutting laminate can result in 10-40% material savings.  That’s a big deal considering the proportionally high cost of PVB vs. Glass.  Often our laminate cutting system’s will pay for themselves in the first few months.

While Carlson Design offers a range of nesting and autonesting software, Carlson Design worked with Oldcastle to integrate their glass nesting software company, PMC Software, into the system.  PMC is the industry leader in glass and window nesting and optimization software.   They input the incoming glass rack number and PMC oversizes the lami-cuts and autonests the pieces across different roll widths ranging from 96″-36″.  This highly effective method of nesting results in 80-95% material yield.  When they are ready to cut, they simply pass our software a *.DXF file.

Heather from PMC made sure the PMC software seamlessly handed Carlson a cut-ready file.

In addition to material savings, layups are also much faster because there is no need for post trimming.

After cutting nested parts, the plotter/cutter parks out of the way. Cutting is now an entry level position.

Parts lift right out, ready for layup. This reduces material handling.

Large parts layup without trimming, spinning glass, and no longer require two people. "Yawn" this is so easy now!

Precision fit. You can size your cuts to fit exactly on, or slightly increase/decrease material size to accommodate your lamination technique.

Small parts or parts with multiple layers are now much easier to layup.

In the end, it's all thumbs up!

That looks easy…but how do you get started?  When integrating a plotter/cutter into a clean room, typically the first concern is space.  The plotter/cutter will take the place of your existing cutting table.  Our cutting tables do not require access to all sides of the table, so you can often work the system into a corner.  Our plotter/cutters are available in widths from 48″ to 168″+, but average sizes for lamination are 72″, 96″, and 108″.  Let your average or max laminate roll width determine your table size.  Oldcastle selected a 108″ wide machine to cut their 96″ wide PVB and SGP.

Let’s look at their install.  When your Phillocraft vacuum table arrives, it will look something like this:

Phillocraft tables come in endless 4' long sections, sized to width. Broken down, they can easily be carried through even the tightest clean room door.

Clear a spot and carry the individual items into the clean room. Try to plan ahead to reduce the number of trips.

Layout your parts, starting with the legs.

Layout the rest of the table parts. This will help you get a sense of where the table will sit in the room and will speed up assembly. Note, for tables wider than 96", the table frame is broken into multiple widths, as well as lengths.

Begin assembling the table. Two people make this go much faster - thanks Ben! The entire installation will take about eight hours, so plan to have your cutting area out of commissioning for at least one shift.

Assembly panorama

Framing continued.

Framing complete! Before adding the table tops, it is important you position your table where you would like it to remain.

Once settled, add the table tops.

Square and level your table. Now you can tighten all nuts and bolts.

Attach the vacuum plumbing. In a clean room, we use flexible plumbing so that additional vacuum can easily be added if needed. It is common to use smaller HP blowers to limit the amount of air stirred around the room.

This 1.5HP, single phase 115vac blower is sized to provide enough suction for a table completely covered with non-porous laminate.

Mount track side A. Please take the time to clearly follow the track installation instructions.

Pull out your plotter/cutter. Admire. You will use the machine as a jig to square your track.

Attach side B.

Your plotter/cutter is almost installed. Prepare your cutting surface by first laying down strips of vacuum breather mesh. This will allow air to flow between your table top and cutting surface.

Attach plastic cutting surface. The cutting surface is secured with packing tape. Flip and rotate sides until you discover the best fit that offers the smallest gaps between sections. Often, the plastic at the front of the table will wear before the end. A good solution is replacing the first 1' of cutting surface with a narrow strip that can quickly be replaced as it wears.

Assemble your operator's workstation. The workstation can be any area where you can place a monitor, keyboard, and computer. We like to use tuffy carts on wheels, with a lockable storage container and wide screen monitor. Our computers tuck nicely inside, along with manual and spares kit. Unfortunately our PC was not setup for their network during the training session, so we used an old existing tower PC from someone's office. Carlson systems are very flexible!

Finally, install plotter/cables and cable management. It may take a week or more of actual production to determine exactly where you want your workstation. Once you've selected a final location, then you can run more permanently secure your cabling. To start, hang them off the side of the table with the least traffic. In time, these can be run overhead, under the table, or left as is.

Ta Da! You have successfully installed your plotter/cutter. Tomorrow the training begins.

Close up.

First cut.

Different angles.

To begin training, we recommend gathering everyone who might interact with the machine for an introductory session. We start by explaining what's what.

Group training is important, but only for the first session. After this, we need to select our "go-to" operator.

Training a specific operator is ideal. They will be our contact for service and support -- even if they don't actually service the machine. Our systems are very simple, so most learning occurs through repetition. Over the course of an install, there is typically only time for one person to really become a proficient operator.

Once trained, this person can train others to use the system. In a production environment, it is not uncommon for there to be multiple operators, over multiple shifts. Teaching is one of the best ways to really learn something.

Final thumbs up! Big thanks to Roy, Phil, Rick, Todd, Heather, and Benjamin for all their help making this a successful install. Happy cutting!

In St. Cloud, we met Marie Omann and her son Joe to install their new Plotter/Cutter.  We started speaking with Marie months earlier about automating and over the summer we met her and Joe at a technology trade show in Fort Meyers Florida.  Early in 2012 Marie noticed a growing demand in her custom cover business for ATV covers, Boat Covers, and upholstery at the local hospital.  To meet this growing demand and to begin laying the foundation for transitioning her business from mother to son, Marie was looking for a system she could use to digitize her existing patters, begin working with CAD, and automate her pattern plotting and cutting.  They chose the Classic Carlson Design CTx-72 Plotter/Cutter, T-Bar pattern digitizer, on a 6′x28′ long Phillocraft vacuum table.

Joe and Marie with their new CTx-72 plotter/cutter and 28' long Phillocraft vac table

When Marie began her search for an automated cutter and pattern digitizer, she did not have any formal CAD or CNC experience.  She knew another local shop used a 3D digitizer to pattern and then high-ply cut.  However, for her shop, she wanted something that was easy to use, easy to change, and could quickly cut one off and repetitive patterns.

During our meeting in Fort Meyers, we outlined a clear path to automation.

Step 1:  Digitize Existing Patterns with our manual 2D pattern digitizer.

Joe digitizing! The T-Bar slides in the same track as the plotter/cutter, allowing the operator to manually trace patterns as large as the vacuum table.

Using the our T-Bar digitizer, we started digitizing their existing patterns for a new large order and older recovers.  During training we cut ATV cover parts Marie could immediately sew.

First Run!!!

Step 2:   Replace her existing home-made table with a seven section, steel frame, Phillocraft production vacuum table.

7 section frame before dropping in tops.

Marie debated using her existing table wooden frame table.  We also offered plans for her to build her own, new vacuum table.  Joe is handy with wood, metal, electrical, and plumbing, so they weighed this option pretty seriously.  Eventually, for the cost and time, they decided to get our vacuum table.  Once setup, Marie exclaimed, “Wow, now THAT’S a nice table”.

"Now THAT's a good looking table!"

Step 3:  Selecting a plotter/cutter.

Classic CTx-72 Plotter/Cutter

Marie is working with 54 and 61″ wide fabrics, so it was easy to select our standard 72″ wide cutting system.  Looking at her current volume and planning for growth with Joe, well into the future, they selected our Classic CTx-72″ plotter/cutter.  The Classic is ideal for cutting most woven fabrics including acrylics, as well as non-wovens like PVC.

Cutting a nest in PVC

Step 4:  Computer, installation, and training.

Carlson Plotmaster Software Suite runs on most Windows XP or 7 PC.  Having recently purchased a new laptop, Joe decided to load and configure his own PC.  This allows him to pattern anywhere, and not just at the cutting table.

Like the table, to expedite the “learning curve” and get cutting as soon as possible Marie asked us to come to St. Cloud and setup their system.

For the first day we setup their cutting table:  http://carlsondesign.com/blog/phillocraft-vacuum-table-assembly/

For the next two days we digitized full pattern sets, edited, nested, and then cut full tables.

Full table nests! We cut 7 pattern sets in one hour. By hand this would have taken 5 hours or more!

We had a great time working with Marie and Joe at Prodesign and we can’t wait to see how they use their Carlson to grow their business in the coming years!

When you first power on your computer, hit the appropriate key for your computer or BIOS manufacturer.  Please see the tables below for the key to access the BIOS setup for many common computer brands.

If your computer is not listed above, there are some common key functions that can be used to access the computer’s setup (BIOS) on most brand name computers.

Many computers display BIOS access instructions while the computer boots. Pressing a key or a combination of keys before the Operating System begins to load will access the BIOS. Some common keys are ESC, F1, F2, F10, Ctrl-Del or Del. For more information, check the documentation that came with your computer to find out how to gain access to the computer BIOS.

If you are still unable to access the computer BIOS, please refer to the documentation that came with your computer or contact your computer manufacturer for more information.

Once you are in the BIOS setup:

1. Locate the parallel port mode setting in your computer Setup. The parallel port mode settings may be located in the Advanced Settings section, Peripherals, Communication or Input/Output sections.
2. Select EPP mode.
3. Exit out of the computer setup, making sure you save the changes.

Compaq computers with Compaq BIOS (setup) will not allow you to change the parallel port settings. You must disable the DMA channel, which will cause the parallel port to change to EPP mode. Turn off the DMA channel assigned to the port and use the same hardware configuration that the current port is assigned. This will change the mode from ECP to EPP.

Example: Change 0378-037F, IRQ 7 DMA2 to: 0378-037f, IRQ7.

Note: On some older Compaq computers, it may not be possible to assign the parallel port settings without a DMA setting. If this is the case, contact Compaq for a possible BIOS upgrade.

The School of Constructed Environments found everything they were looking for in the Carlson Design Studio, STx-72″ plotter/cutter.  Let’s see how:

Versatile?

The Studio uses Carlson Design "magnetic mount" cutting tools and quick-change pen holder. This allows Students to quickly and safely change blade holders without tooling.

On the same table; instantly switch from cutting .030" or .050" chipboard for model making to Muslin used in pattern making.

Here’s a quick, uncut video of the Studio plotting and cutting chipboard and then cutting muslin:  https://vimeo.com/44249067 (If video is slow, please give it a second to load or sign into vimeo.com –free– to download the video).

This large table can be even more versatile with the addition of our T-Bar Pattern Digitizer.  This is great for tracing physical patterns that would be difficult to draw on the computer.  Does your latest design finally fit your model?  Lay it flat, digitize, and now you have a computer model ready to scale, modify, or repeatably cut.

The T-Bar Digitizer rides on the same track as the Studio.

When asked why he chose the Carlson, the Director for Modeling Facilities and assistant professor at The School of Constructed Environments, Mark Bechtel said, “At an art and design school, there is a very high demand for laser cutters for a wide variety of different cutting applications from architectural model making to experimental fine arts work to fashion design. I wanted to find a comparable alternative for the majority of demand that could be easily relocated to support changing curricular needs. Aside from the benefit of new types of cutting processes such as creasing, this machine is also a cost effective solution since it does not require a dedicated exhaust system.”

Small foot print?  Light Weight?

Our Track comes in short sections and can mount to almost any table top and/or even the floor.  If you can secure your material without vacuum, then any 6′ wide flat surface can become your work area.  Since the plotter/cutter only weighs 16lbs, it’s easy to move to different locations.  Some might think a “light weight” gantry means “light duty” performance.  Our captive track and vertically oriented motors secure the plotter to the table and the job.  This makes the studio as industrial as it is practical.

The Gantry only weights 16lbs

At Parson’s the Studio is riding on a two section, Phillocraft vacuum table – 6′x8′.  These endless, steel frame tables can easily be reconfigured with more sections or into a single section.  In the Fall, they plan to turn this 6′x8′ table into two 6′x4′ tables.  The modular foot print allows the Studio to operate in different sized classrooms.

Castered Wheels make it easy to move the plotter around the classroom.

Simple to maintain, operate, and service?

Carlson Design software and hardware is designed to be very simple, and therefore reliable.  The NEW Studio’s hardware is a study in simplicity and providing high reliability and easy service and maintenance.  It uses plug-and-play, off-the-shelf components that hang from easily removable holders, “snapped” on to the back rail.  Because these are off-the-shelf consumer components and not obscure, industry specific motors and drives, they are extremely durable and affordable to replace.

Most of the components are "Pluggable" and the tools and parts to replace almost every component on the machine are available in our Spare Parts Kit.

The light weight frame has several other advantages — in addition to reducing component wear-and-tear, if something cannot be repaired, the Studio is small enough to be shipped UPS or Fedex back to Carlson for repair.

Our software is very intuitive and can be “preset” with optimum settings for different materials.  Once configured, a student can select their material (ie. “.030 chipboard”), select their file, and hit “Plot”!

Our Plotmaster software will run on any WindowsXP or 7 PC.  This means students can download Plotmaster, prep their pattern on their own laptop, on their own time, and simply network the cut file or “plug” directly into the Studio’s USB cable when they are ready to plot.

Parson's provided their own Windows7 PC and monitor.

Better than a laser?  Safe to use?

The Studio has several advantages over traditional laser cutters used in model making.  Lasers produce fumes and need to be vented.  Implementing venting in a large city, in old buildings, were students are working can be expensive.  Think unions, inspectors, city code, OSHA, the works!  It also greatly reduces the system’s mobility.  This also means the laser “bed” needs to be enclosed which significantly reduces working area.

The Studio uses rolling and drag blades which do not create fumes and do not require venting.

Since the Studio uses drag blades, it can cut small parts that would be burnt or vaporized when using a laser. The laser can also set-fire-to or brown the edges of textiles, limiting their versatility.

Limited torque motors and recessed "pinch points" make the machine safe for any operator to use. The controls are easy to read and easy to reach.

Those are some pretty good reasons to pick the Carlson Studio.  Let’s now see how we setup their system:

The cutter arrives on a pallet. The components are removed and moved individually to the 6th floor.

When setting up a Phillocraft vacuum table, the first step is laying out your parts. This will save a lot of time and turns the setup into a one-person job.

Phillocraft tables come with a big bag screws. Don't worry you only need a 1/2" and 3/4" socket. Separate into three piles -- 3/4" nut and bolts for the feet, table top screws, and 1/2" nuts and bolts.

The tables have endless steel frames. Identify the ends by the sections with angled edges.

These are the lower braces. They mount at the bottom of each leg, across the width of the table.

The upper cross member connects table sections. The mounting order from inside out is: Leg, Upper CM, Table Frame. If you only setup a 4' long table you will not use these middle pieces.

Long straight braces go from Upper Cross Member to Table leg. This is a good example when laying out parts near their location will help the table assembly go a lot faster. "Pre-connecting" these support can be helpful.

If your table is short, you can attach casters to the feet to make it more mobile. Long tables and production tables need to be leveled for optimum performance.

Assemble frame. Finger tighten all 1/2" nuts and blots.

Six metal spacers slide between each adjoining top. Insert tops to square frame.

Before tightening, make sure the wooden tops are aligned and square. This is more important than the metal frame looking square.

Square the the frame. A magnetic level is very helpful.

Using the level, tighten the frame as you go. An impact drill with 1/2" socket makes this a quick and painless process even on long tables.

When the table is square and level, you can attach one side of your track. Visually align the track so it is as straight as possible. Follow your track installation guide closely -- this is important. Mark and drill an 1/8" pilot hole.

Hand tighten your track screw. Check alignment before drilling the next hole.

Once "Side A" is secure, slide the plotter/cutter on the table and use it to align and mount "Side B". See your manual for more detail.

Clean the edge of your track and apply double-sided tape.

Clean your track belt THOROUGHLY with acetone to remove oils and insure good adhesion to the double-sided tape. Attach the belt with even pressure on both sides. The belt has "peaks" and "valleys". Try to start both sides on a "peak".

Install Blower. This is a 1.5HP, 115vac, single phase blower. We mounted it off the floor to make moving the table easier.

Smaller blowers can use 4" flexible dust collection hose.

Connect plumbing as shown in your manual.

Use silicone or calk to prevent leaks between your table and universal fittings. Wrapping your connections with stretch wrap can also reduce leaks. Plugging leaks significantly improves vacuum performance. Wafting "incense" under the table and watching the smoke is a great way to identify leaks.

There are a variety of different techniques for cable management. The most common is "overhead", however for short, mobile tables side mount cabling can be a great option. Replace one of the table screws on each end of the table with a 1/"x4" eye bolt.

Slide your pulleys on the cable and string. We recommend one pulley every 3-5 feet. use a turnbuckle on one end to tension.

If you haven't already, insert track stops. Tighten very securely.

Load your computer. Free updates and downloads for Plotmaster are available on the internet to licensed users.

Attach your airline to the quick release pneumatic fitting provided. Attach the fitting to an air source. You need at least 90PSI and 1CFM. If you get a small tank air compressor, make sure it's quite so it does not disturb the operator when it "kicks on". Set your pen and cut pressure to the indicated marks.

Usually here we would say, “attach your cutting surface”.  We like to use 1/16″ polyethylene or polypropylene for most applications.  These surface are inexpensive, hard enough for most textiles, but not too hard to quickly dull rotary blades.  You can read more about which cutting surface to choose here: http://carlsondesign.com/blog/choosing-a-cutting-suface/.  If you purchase a table from Carlson Design, we usually include cutting surface pre-drilled.  Unfortunately the shipper thought OUR plastic sheets on the pallet were for shipping protection and they never made it to the room.

DON’T WORRY! You have a plotter and finding cutting surface locally is never very difficult– even in NYC.  At the local hardware store we were able to find sheets of acrylic.  Acrylic is not our first choice because it is brittle and a harder on blade life.  After a few funny looks on the subway we were ready to plot and drill our own plastic cutting surface.

Make sure your plastic is cut 6 or 7 inches narrower than your table width. Contact Carlson for a drill pattern. Using a permanent marker, mark the top of your plastic. Stack all the sheets and drill using an 1/8" or smaller drill bit, drill the intersections.

Here is a quick video of the Stuido plotting it’s own cutting surface:  https://vimeo.com/44249068

Cutting surface vacuum holes and table top vacuum holes may not align. Placing a thick, woven mesh on the table will help create a vacuum channel and improve air flow.

Attach the cutting surface. Your plotter/cutter is now installed, ready to get to work.

Now that our system is installed, let’s look at a few “beauty shots”.

First Cut!

The Studio has a 64" plot/cut working area. This is a little wide for most chipboard, BUT ideal for most textiles. Very versatile indeed!

Second Cut!

One for the road!

Thank you Parson’s and Mark Bechtel for making this a great install.  We cannot wait to see what the New School Students make with the Studio in the fall.  Stay tuned.

Yoshimura Carbon Fiber muffler tips

Talking to their carbon fiber specialist, Mike Biere, about their current and future plans for in-house carbon cutting, we decided to produce a new industrial version of our Pro model PT-72, called the PTi.  The PTi would have more power, a stiffer frame, and a larger and more rigid cutter.  This robust model would ensure they could keep up with their growing demand for carbon fiber parts.

Two good looking models!! The PTi side-by-side the PT. Note the PTi's taller frame rail, custom load reducing drive plates, larger Y and Z motor, and custom drive belt.

Before we tell the story of the PTi install, let’s skip to the end with a quick glamour shot — pretty awesome right?

Sample material -- carbon Fiber and Kevlar weave -- really hard to cut by hand.

Now on to the install — the table and cutter arrive separately.  Setting up the plotter/cutter takes an entire work day.

Start unpacking.

Laying out the table frame before assembly will make the process go a lot quicker. The table uses one size nut and bolt throughout, so if the parts are in the right place screwing it together is very easy.

Once assembled, leave all of your nuts finger-tight. Position the table where you want it and then insert the vacuum tops. Manually adjust the table so legs and tops are visually square.

A magnetic level is great for quickly squaring the frame. All the nuts are self locking, so you can tighten the bolts quickly using a drill or impact driver with a 1/2" socket. This is also good Nascar pit crew practice.

Once the frame is level and square, mount the track. Attach one side and then use the plotter/cutter to square the other side, securing as you go. Clear away any debris, wipe down the track and belt with acetone and attach the track belt to the metal rails.

Use a vacuum breather between the table top and cutting surface to create an air channel. Thicker, woven mesh is best. This is molded window screen.

Following a tip from one of our customers, we replaced the window screen with this dish drying mesh used by restaurants and bars. The thicker weave made a big difference. You could even hear a significant improvement in airflow. Woosh!

Attach the plumbing. Securing carbon fiber during cutting requires a lot of vacuum, so you must use rigid pvc.

5HP radial vacuum blower with 8" to 4" reducer.

Securing your carbon fiber prepreg during cutting is a big deal.  This can be a difficult for several reasons.  First, your prepreg has been rolled up in a freezer and while it’s still cold it does not want to lay very flat.  Next, thicker prepreg is a sticky, hard to cut material, which means you need to put a good amount of pressure on your drag blade to get a complete cut.  This pressure can drag your prepreg if not properly secured.  Finally, carbon is expensive, so you will try to nest parts as close together as possible to ensure maximum material yield.  You will lose material hold as you make more and more cuts — if you vacuum is undersized, this can cause tightly nested parts to shift or drag.

For thinner carbon fiber K3, fiberglass breather, and very sticky prepreg we were able to use a single 5HP radial vacuum blower (pictured above).

5HP blower plumbed

Unfortunately the heavier carbon fiber prepreg k12 had a tendency to shift.  To resolve, we replaced their single 5HP radial blower with two 4.5HP regenerative blowers.  These are lower volume, but have 7X the pressure.  They did the trick, allowing for tight nesting without any material shift.

If large vacuum blowers are not available, 3M makes a reusable semi-adhesive tacky spray you can use to glue your material down during cutting.

Once setup, attach your cabling. In large open factories overhead cabling might not be practical. Using 4" eye bolts we mounted their cable off one side of the table.

Securely tape your cutting surface to the table top. They are using 1/16" polyethylene with a3"x3" hole pattern. Be sure to cut your cutting surface 4" narrower than your table width. Your plotter/cutter and vacuum table are now ready to use!

It’s time to setup your software.  The new 2012 Plotmaster USB software — PMU — will run on any Windows PC.  We can provide a Windows7 PC, preloaded and tested or you can provide your own.  If you use your own computer, we recommend making it a dedicated machine — this means leave Itunes and AOL at home!  We also recommend you connect your PMU computer to the internet for the latest updates, purchasing consumables online, virtual help and training sessions, and checking out blogs like this one.

We provided Yoshimura with a preloaded and test Windows 7 PC. They provided the monitor and have plans to build a more formal workstation. For now the table behind the cutter will work.

You can draw patterns using almost any CAD program or manually create patterns using our T-Bar Digitizer.  The T-Bar is ideal for tracing existing patterns or manual prototyping where unusual shapes might be very difficult to draw on the computer.  Yoshimura’s R&D department has CAD designers and a T-Bar.  The T-Bar lets the plotter/cutter operator, Dustin, digitize jobs without any assistance from the CAD draftsmen.  They also had a large collection of physical patterns that are now stored digitally.

The T-Bar is setup to digitize one of their more popular muffler tips. This shape looks like a circle, but it's not. The T-Bar makes sure they get an exact match.

The T-Bar can digitize patterns as wide and as long as the plotter's table. A piece of glass or clear plastic is great for securing small patterns during digitizing. The T-Bar is powered by USB and easily slides off the table when not in use.

T-Bar and Plotter/Cutter. The Tbar will digitize plot and cut lines. You can also digitize multiple patterns in a single session.

One more look at that PT!

If you are curious about that picture, here’s the video of that run:  https://vimeo.com/40120697

With the cutter in-house, Yoshimura R&D is now setup to cut hundreds of sets a muffler parts each week.  They can also prototype new styles, new carbon fiber types like the yellow kevlar weave featured above, and test cut lots of other parts they may want to start making out of carbon fiber.

Big thanks to Mike, Dustin, and the rest of the Yoshimura team for making this a great install.  We look forward to seeing what incredible carbon fiber motorcycle parts you all produce in the coming years.

Thanks to the help from everyone at Litania, this was a great install with great results.  Our very first run reduced cut times by a factor of 10 from 30 minutes to 3!

Here’s a quick video of that innageral run:  https://vimeo.com/39737338

They are cutting 14oz vinyl with a 28mm steel rotary blade.

After running for 4 months here’s what the production manager had to say:

“Thomas,

Sorry for the late response.  We have hit our busy season and emails are flying in and out.  Slipped through the cracks.

Everything is going great.  We did have a air solenoid go out, but that was a pretty easy fix, and it was in the spare parts kit.   We also broke off the step down air nipple off the compressor (stole from the bad solenoid).

I would certainly like to give you some feedback on the cutter, just don’t know where to start or what to say.

Watching patterns being cut before the Carlson Designs cutter was installed was a painful process.  It was like watching a caveman cut the first animal skins with sharp stones!  Definitely required skill and an eye for detail to ensure everything was correct.  Since the cutter was installed, I have taught three people to cut patterns.  Can you move a mouse and click a few things?  Yep, you’re trained too!  As stated before, we are now cutting jobs in 3 minutes that took us 45 to 60 minutes to cut.  This has freed up valuable resources to help in other areas.  But, what is best is that we are turning out consistent product.  Cut pattern number 1 is exactly the same as cut pattern number 400!  Moving a sew line with a hard template required rebuilding the template.  Cutting something out was left up to the person sewing.  Now?  Give me five minutes and I will update the drawing for you.  We are systematically reducing the extra steps that a seamstress would have to take in trimming, clipping, cutting…..  We haven’t even scratched the surface of where the Carlson Designs machine is going to take us.

One other thing.  I am now looking at everything differently based on one thing you said several times when you were here to install…..  When I look at a part that looks like we are having trouble with, I always remember what you said, “It can be more complicated”.  This reminds me to stop and think that KISS is so true!  Why do we sew this part this way?  Easier stitches make faster pads, which means more volume….and more $$$.

Thanks,

Justin M. Vecchio”

OK let’s see how the got started:

We arrive to a framed table with the tops already inserted. The Electrician is busy wiring the motor starter for the blower.

Litania purchased a 6′x16′ long Phillocraft vacuum table.  This is an endless frame comprised of 4′ long sections, allowing them to extend the table later by adding more sections.  Our vacuum tables are typically ready to ship ahead of the plotter/cutter and can be assembled before we arrive.  During onsite commissioning, we like to spend as much time training as possible, however training cannot begin until the installs complete.  Having the table screwed together will shave 2-3 hours off the install and is a great way to ensure training can begin on the first day.

Before tightening all the nuts and blots, it is import to square and level the table. A level table is a fast table. We are using the production manager, Justin's, car jack to level the table.

Once level, attach one side of your track.

Use the plotter/cutter to ensure the other side is parallel.

For the second side, move the plotter/cutter down the track, drilling and securing each track hole as you go.

To advance the plotter/cutter, push from the center. Check the machine is still square before securing the next track section.

Once the track is installed, cover your table with vacuum breather. You need to create an air channel between your table top and cutting surface.

Woven breather is much more effective than molded, and the thicker the better. This is bar mat and can be found at your local restaurant supply store. We chose "Electric Green".

Add plastic sheeting. This is 1/16" thick polyethylene with a 3"x3" hole pattern. Cut your plastic sheets at least 4 inches narrower than your table width. When the sheets start to wear, you can flip and/or rotate them to prolong their life.

Attache the plumbing. Smaller blowers can use flexible dust collection hose. Larger blowers need rigid PVC plumbing. We are using 4" PVC pipe.

Caulk or silicone the face of each flange before attaching to the bottom of the table. This will help prevent leaks. Wrapping joints with plastic stretch wrap will also help. Once the plumbing is installed, wafting smoke under the tables can help you identify any leaks.

Install the blower. This is a 5HP, 3phase, radial blower. It is low pressure, high volume and great for securing vinyl. Many customers will build an insulated box around their blower to reduce noise.

Have your local electricain wire a motor starter near the operator's workstation. The starter can be mounted to the table.

Hook up your air. You can use shop air or a standalone air compressor. You need at least 90psi and 1 CFM. It's not a bad idea to add an oilier and water separator to the line. Your tool box comes standard with a quick disconnect fitting and 1/4"NPT fitting.

Run your cabling. You can run it on the side or over head, depending on your shop layout. Use one pulley for every 4-6' of cable. Side mount is most common in large facilities where there are no close walls to mount the overhead cable. Keep drape to a minimum.

Plug the USB controller into any Windows PC. If you need help, we can provide a Windows7 PC preloaded and tested.

Setup your computer. Install Plotmaster USB (PMU) software. We encourage PMU users to have their system connected to the internet. Here they are using the the table near the plotter as their operator's workstation. Once they understand their work flow they will create a more permanent work area.

You're now ready to calibrate, square, and configure your plotter/cutter!

You also need to select a pattern for your first job. If you do not have a CAD program or any patterns already made, use the T-Bar digitizer to trace an existing hard pattern.

Once you have a pattern, the machine configured, and plotter/cutter installed, pause for one moment to admire a job well done. Good Work! It's now time for your first cut!

After your first cut, it's always a good idea to check the pattern against your original hard pattern. At Litania, Eldon discovered one of the lines in the CAD drawing provided by their engineering department was different from his sewers pattern. We moved the line and cut 6 more sets.

Once parts look good, nest them together to maximize material yield.

Precision cutting typically yields 10-20% material savings.

The team examines their second job's nest. This part set typically takes 45 minutes to complete -- here it was cut in less about 3 minutes.

They placed their own roll rack at the end of the table. this makes switching between colors quick and easy.

Thumbs up! Thanks Litania!

It was exciting to watch 20-40 minute manual cuts finish in less than 2 minutes start-to-finish.   We cut 6 full pattern sets in a half hour — this would have normally taken a full day.  The parts being delivered at the sewers station are now more accurate and much more repeatable.  Having a computer controlled cutter also allowed the engineering department to get involved.  They can now make changes and improvements to patterns in real time.

A big thanks to Justin, Eldon, and Ralph for making this a great install!

Litania selected Carlson Design because they were able to send us sample patterns and material that we digitized, cut, and returned the next day: https://vimeo.com/36582270 .  If you would like to see your material and patterns test cut, please do not hesitate to send something our way:

• Carlson Design
• 539 S Trenon Ave
• Tulsa, OK 74120

Peter’s an active user of our equipment for the last five years and one of our featured “success stories”, so it was great to finally meet face-to-face.

Peter Shows around the loft!

In 2007 Peter built his own table and installed his own system.  You can see a video of Peter’s install here:  http://carlsondesign.com/vacuum-tables/build-vac-table

The table has a skirt to hide fabric rolls and reduce noise from his vacuum blowers mounted under the table.

Peter uses simple "O" rings for his control, power, and air cables to ride above his plotter table.

Five years old and no problems. Peter has not replaced or repaired any parts but blades.

Glamour Shot #2

Here’s a quick video of the CTx-72 in action:  https://vimeo.com/37210964

Peter uses the T-Bar digitizer to create digital files from existing hard patterns.  You may remember our post from last summer regarding the humane Mexican turtle traps he made using the T-Bar:  http://carlsondesign.com/blog/peter-green-sails-uses-plotter-for-eco-project/

Peter's made a few custom modifications to his T-Bar. He made a platform for his laptop so he can digitize and edit files in a stand alone setup.

Finally, before heading off to Merilyn’s lunch, we snag one last picture of the man himself running his Carlson plotter/cutter.

Thanks Peter!

We appreciate the Green’s hospitality and it’s always great to see one of our systems in action.  Great setup Peter!  If you would ever like Carlson Design to visit your shop or feature your cutter on our website, please let us know!

Their primary driver behind purchasing a digitizing/plotting/cutting system is to produce more accurate, repeatable patterns, more quickly and with less material waste.

OK – before we walk you through their install, here’s a quick look at the final product.  *Spoiler alert:  It’s awesome.

PT-84" Glamour Shot.

They are going to use our T-Bar Digitizer to trace years of physical patterns and create digital, ready-to-cut files (picture of pattern library later in the post).

The T-Bar rides on the same track and table as the cutter, allowing you to trace patterns as large as your cutting bed.

You can see Josh digitize his first pattern and then plot and cut using the PT-84 in under 5 minutes:  http://vimeo.com/34858726 (This video was shot in HD, for the best viewing experience, please give it a minute to load).

Say “goodbye” to Josh and let’s see how they got setup.  To Start:

Before we arrive they loosely assembled their table frame. This time saving trick means more time for training!

Once the frame is assembled, position your table where you want it. Insert the vacuum table tops and align the edges. You are now ready to square, level, and tighten the table frame.

Attach the first side of your plotter/cutter track. Follow instructions -- it is import that the track is as straight as possible.

Use the plotter/cutter as a guide to attach track on the other side.

Before we arrived, they also mounted the two, 5HP regenerative vacuum blowers on the roof.

Advanta is cutting polyester, wool, and vinyl.  The majority of their material is a high thread count, porous material.  Therefore, we sized two 5HP regenerative blowers. These are plumbed in parallel (in the photograph) and mounted on the roof, about 30 meters from the table, although a closer mounting would reduce losses.  They will remain outside for noise reduction/cancellation. Regenerative blowers are a little more expensive, but a great choice if you need a lot of suction.

They have around 30 meters of plumbing running from their vacuum blowers on the roof to the bottom of the vacuum table. It is important to check every joint and connection for leaks to prevent vacuum loss.

Plumbing runs to the center of the table. Add blast gates to create different vacuum zones.

They setup each motor with its own starter. You can use one or both blowers depending on your table coverage and material density.

Add cutting surface to table.

Run Overhead Cabling. Make sure you use a nice "sailing-hardware" grade pulley for your lead over-head cable pulley.

All Done! Remember me?!

Time to start digitizing that enormous hard pattern library.

Phil digitizes his first pattern. The T-Bar has two buttons to allow the operator to digitize plot and cut lines.

Now it’s time to start training.  Everyone pull up a chair…and they had some great chairs!

"Take a seat, please." They make great looking chairs like this one.

Advanta Team. Phil, Josh, and Ben. Phil's a little camera shy...

You may notice their cutting surface looks a little different.  In an effort to eliminate material hangers caused when a rolling blade hits a vacuum hole, they went with a laser drilled, mircro-perferated cutting surface.

Microperferated Cutting Surface

Unfortunately, the high thread count nature of their material and the soft nature of the cutting surface resulted in the blade rolling over the material without fully cutting.  The solution is a combination of a harder cutting surface or something between the cloth and cutting surface like butcher paper.

Cutting is improved with very high thread count materials by putting paper between the cloth and cutting surface.

Harder cutting surface like Polyethylene or Formica.

It’s a long journey to Western Australia, however the staff at Advanta made us feel at home, “down-under”.  We think this is a great application for our equipment and look forward to watching their success.

For more information about how to automate your cutting, please contact us at info@carlsondesign.com.

Marco Canvas represents 4 generations of sewing tradition since the 1920′s, but current owner Ed Srzynski is not looking to rest on the coat tails of his forefathers.  His Six Sigma training and eye to the future keep the company continually improving.  A familiar saying of Ed’s around the shop is, “The only thing everyone here knows is constant is that things are going to be changing”.

Last week Carlson Design was excited to be apart of Marco Canvas’s latest change and step toward continual improvement when we installed and trained the entire Marco Canvas shop on our digitizing, plotting, and cutting system.

To start — after increasing the foot print of their 2nd story mezzanine, they cleared out their old cutting table to make room for our steel frame vacuum table.  We help many customers build or convert their existing tables, but based on their schedule purchasing our table was an obvious choice.

Marco cleared a space for our 6'x28' vacuum table. You only need access to 2 sides, but it's nice if you can walk all-the-way around.

Laying out the steel frame before you get started is a good practice and will ensure everything is accounted for and in the right place

Assembly is easy with 2 people. The entire table uses the 1/2" nuts and bolts. Finger tighten. Available in endless 4' sections, you can always make your table longer.

Like an 'Erector Set' for adults, assembly goes quickly. Now is a good time move your table exactly where you want it.

Set composite table tops on the steel frame. Place steel connecting tabs between each top.

Once all the tops are in, you are ready to square the frame and tighten all nuts.

Using a bottle jack or car jack, find the table's high point and level both sides. This is an important step.

Silicone pipe flanges and attach pre-cut PVC plumbing to the bottom of your table.

Attach Blower. This is a 5HP, 3phase radial blower. Different blower configurations are available depending on your application.

Have your local electrician ready to wire. Place an on off switch on the side of the table with the computer.

Your control cables can be run from a cable suspended over-head or off one side of the machine. Overhead is simple. Run a wire above head level down the center of the table.

Mount your track. Follow instructions closely! You're almost ready to start plotting and cutting.

Cover table with cutting surface. There are lots of different kinds, but 1/16" Polyethylene is the most popular. This should last 1-4 years and can usually be found locally.

Pat yourself on the back...It was a long day but you did it! A Carlson Design PT-96" Plotter/Cutter on a 6'x28' phillocraft vacuum table.

Time for training!  Ed gets the entire team together for group training.  They are still deciding what their operator’s workstation is going to look like, so for training we setup Ed’s projector.  A great tool for training large groups!

Plotmaster on the big screen! Coming to a theater near you...

First impressions. Everyone meet the plotter/cutter. Plotter/cutter, meet your new family. Training start with an orientation.

Learning is hands on. Everyone takes a turn driving -- here Ed takes his turn. A desk is in the works ;D

Using the plotter/cutter is intuitive, however what to cut isn’t.  Most first impressions are that the plotter/cutter is only for large jobs or repetitive work.  Not so!!  The plotter/cutter makes every plot and cut accurate and repeatable.  Once a pattern is stored electronically it can easily be recut for recovers or modified to fit a similar job.  How do you integrate into everyday operation?

Using the Carlson T-Bar Digitizer, you can quickly trace existing hard patterns to make a ready cut file or a file ready to be edited or modified in any CAD program.

Ed covered his pattern with a sheet of plexi-glass to prevent shifting during digitizing. This Yamaha V6 4Stroke 2010 motor cover is very popular. Once digitized and nested it cut in under 2 minutes.

The Marco Canvas team with their newest member!

Many thanks to Ed, Tammy, John, Juan, Joz, and the rest of the Marco team for a great week in Marco Island Florida.  Keep on eye on these guys as leaders in innovation for the marine canvas industry.

Right before Thanksgiving we had the pleasure to install systems at Ultraglas near Los Angeles, California and Tacoma Glass in Tacoma, Washington.

Let’s start with Ultraglas…

Ultraglas founder and owner, Jane Skeeter, is a pioneer in the decorative glass business and well known for taking on interesting and challenging project.  Her creativity is evident when you first walk in the door by the wide range of products on display in her show room…

Show room Filled with possibilities!

Where art meets glass...

Ultraglas uses the Hoaf lamination line which is an Autoclave-free modular system that cooks laminate in batches.  The Hoaf is ideal for custom lamination where each job might call for a different thickness or laminate type (and therefore need different heat or cook time).  Our cutter will help them cut specialty shapes for custom projects or repetitive shapes for high volume.  It will make cutting very accurate, clean, and so easy that it becomes an entry level job anyone in the shop can preform.

While we we’re there we saw Daniel Jessup of Salem, a familiar face from the glass show, putting the final touches on their oven.

Hi Daniel! He's putting the final touches on their modular Hoaf lami-oven.

Ultraglas’s Carlson system is very similar to Tristar’s — a PT-96″ Plotter/Cutter riding on an 8′x12′ vacuum table, however they turned their table sideways to accommodate pulling laminate from 2 different climate boxes.  This allows them to quickly pull color or clear interlayer onto their cutting table.  To maximize training time during install, they pre-assembled their table and vacuum plumbing before we arrived.

Level vacuum table with flexible plumbing attached to a 3HP, 3phase blower

Upon arrival, we installed the track, track belt, plotter/cutter, and cutting surface

and installed their overhead cabling between each climate box

They provided their own workstation and monitor. Any ergonomic stand or desk will work.

Once installed it's time to start training! Paper is a great material to use when getting started.

Lon takes the wheel. Our software makes creating and nesting simple shapes fast and easy.

First nest cut on paper. Nesting parts saves 10-20% material, which means a very fast ROI when cutting interlayer.

Video of first run:  http://vimeo.com/32848188

Dale and Lon give 2 thumbs up after training

Big thanks to everyone at Ultraglas, especially Jane Skeeter for getting everything ready for productive 2 day install and training.  We look forward to seeing your beautiful laminated glass!

A quick glimpse at the sun setting on Santa Monica Blvd

Good By LA....Here we come Tacoma

Tacoma Glass is known in the area for their quick turn around time.  You call these guys when you need to get the job finished.  They are a relatively new company, but the 3 owners alone have over 50 years worth of industry experience.  They are using the Hoaf Smart Box to laminate — this is a smaller system than the traditional Hoaf oven, however it gives them the ability to replace any piece of laminated glass in a single day.  They plan to use cut files from their CNC glass cutter with their Carlson, so they can cut matching glass and laminate.  This makes for high quality windows produced at record speed with limited specialty know-how required.

Tacoma Glass was great to have pre-assemble their table and have their staff ready for installation and training.  This allowed us to have everything running by lunchtime and we started training the first day.

We square and level the table

Plumbing attached to a 1.5HP single phase blower.

Our systems don't use much air. A 1HP, 2gallon air compressor work great if you don't have shop air.

Overhead cabling can run from the center or side of the plotter/cutter

They used a shelving bracket to mount their overhead wire.

Cutter installeld, ready for training!

PT-96" plotter/cutter on an 8'x12' vacuum table. Great looking setup!

96" wide gantry can plot/cut up to 87" wide material. Great for cutting PVB, EVA, SGP, and many other laminates.

Jim is the first to train - all smiles! Computer and monitor sit on a folding table until they are ready for a permanent wall mounted workstation.

Ricky practices adjusting cutting pressure for different materials. Easy to read pneumatic regulators are mounted on the operator's panel.

Video First Run:  http://vimeo.com/32850188

Ricky, Les, and Jim -- now pro's -- give a thumbs up after 2 great days of training!

This was a great install.  Downtown Tacoma is an exciting city for anyone in the glass world because of the Tacoma museum of glass and the Morano Hotel featuring a different glass artist on every floor.  Special thanks to Jeff, Steve, and Mike for making us feel welcome and thanks Les, Jim, and Rickey for being fun and easy to train.

Mike, Steve and his wife, and Jeff and his Wife take us to dinner to celebrate a successful install!