Rigid Vacuum table build

Wanted to showcase what we decided to build here recently. Our initial table build with a metal table + MDF top turned out to be too flexible, resulting in vertical shifts of up to 0.060" in the table top depending on how hard materials were clamped down (especially if they were warped). This caused a lot of issues with the items we were cutting (mostly dimensional letters).

I previously operated a Gerber Sabre 408 for a number of years so i was spoiled by the rigidity of the machine & the vacuum, so that’s what we’re aiming for here, though the rigidity was the main factor.

To keep it simple, we just used 2"x4" and 2"x6" aluminum rectangular tubing to create the base, with a 1/2" intecel (plastic) topper to mill down and replace as necessary.

Still have to complete the piping and seal the top extrusion for vacuum & drill the holes, but I’ve had this setup for a month now and I am able to cut items out to within +/- 0.002" vertical accuracy (by increasing resolution on the Z).

We cut a lot of dimensional letters out of plastic so the ideal setup is to give the bottom of the sheet a few layers of premask, and cut to the inside of that layer without cutting through, leaving all the final pieces still stuck to the thin layer of mask.

With the new rigidity that is now possible so it’s increased our output massively, no sacrificial materials needed.

Will update later on once we get the vacuum portion finished. It’ll be a big boon for when we cut thin materials.

FYI all the aluminum cost us about $1200 i think.





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Got around to drilling all the holes through the intecel & aluminum today.

Did the intecel hole + target first, then went back and popped in a drill bit for metal & sprayed coolant into the holes first to help it out. Still broke one bit :smiley: Took about 6 hours to drill those 300+ holes.

Did a ‘target’ type air channel rather than a pocket. Reason for this is due to previous experience, i found that pockets will suck in thinner material slightly and throw off cutting. The target does not suffer that problem.

Going to 3d print the caps this weekend and hoping final assembly this coming week.



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Thats super nice. Looks very rigid.

Okie dokie finished it…

Cut and milled some end caps for the aluminum extrusion out of some polycarbonate i had left over, and siliconed them into the ends.

Then finished the the plumbing so to speak with open end left side for suction, open end right side for air release as needed (need a twist end cap for it that can open in sections, will find something or mill something).

Just used a cheap shop vac, we’ll see how long it lasts. Green tape to hold it together, i’ll likely make an adapter later.

First job cutting with the suction. I’m cutting 2mm thick (0.080") non glare acrylic which normally just lifts up in the middle when i’m cutting even with edges held down. No more issues now. In the video i don’t have it clamped down at all but i will end up clamping just corners on thin material so it doesn’t lift when it gets too close to a corner.

Inserted a picture first in case video doesn’t load.

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