instructables

Simple CNC Vacuum Table

by Tucker B

I think that the nature of a maker is to improve and build on other's ideas to come up with your own. This is an
instructable designed to show you how I made this vacuum table so that you can adapt it for your CNC. Because
CNC machines come in all shapes and sizes, the size and shape of vacuum tables will vary greatly so I will try to
make it as versatile as possible.

I made this vacuum table to fit the Rascal CNC and specifically to cut 1/4in foam or cardboard that is about 20 by
30in; however, it can be used for many other materials as well. It is split into quadrants so it can be used for
smaller pieces as well. Also, because it is made from foam, your bit can cut into it and not be damaged.

To build it you will need to be able to rip some lumber with a table saw and CNC a bracket for the hose. Otherwise
it just require regular garage tools like a drill, drill bits, and screws.

It works best with a common shop vacuum. If you suck too much air you risk crumpling your foam.

Supplies:

1in XPS foam insulation (Menards or Home Depot)

PVC about the size of your vacuum hose
3/5in 1 by 4 pine board
Gorilla glue
1-1/4in wood screws
Small scrap of plywood

Simple CNC Vacuum Table: Page 1

Step 1: Design

Sizing

The first thing you want to determine is how big you are going to make your table. I wanted it to cut 20 by 30in
foam board. My machine has a bed of about 35in by 30in so this was perfect. I also left some margin (~2in) just in
case.

Fastening

My CNC table has threaded inserts every 4 inches so I designed my margins to match up with the holes so that
the wood edging can be fastened, down providing excellent stability.

Top Grooves

The grooves were cut with a 1/4in bit and left 1in squares in the middle. This seems to work just fine. It needs air to
move through, but it also needs to support the material especially if it is foam or cardboard.

Bottom Air Channels

The bottom air channels are what actually supply air to the grid. I cut them 1/4in deep and 1-1/2in wide. This
seems to be a good size. Again, its more about getting a vacuum than the quantity or pressure of air. Also make
sure that the channels don't line up with any of your threaded inserts because they will let air in and destroy your
seal.

Toolpaths

I use Fusion 360 for almost everything I do CNC. I use three types of toolpaths for this project:

1. 2D Contour - for the holes that go all the way through cutting halfway through on both sides. I also
recomend adding tabs even though its just foam. I had a chunk go flying. It was exciting. I also used
this for cutting out the bracket at significantly lower speeds.
2. 2D Trace - for the grooves. Fusion has trouble cutting a slot the same thickness as the tool.
3. 2D Pocket - for the channels. I also included a slower cut for cutting the channel in the wood
boundary.

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Simple CNC Vacuum Table: Page 2

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Step 2: Assemble

Cut wood frame Cut foam to size

Rip the 3/4in pine into the thickness of your foam. To
do this accurately you can use the foam as a
reference against the fence of the table saw. You
want them to be as close as possible erring on the
side of a slightly shorter wood frame. If the frame is
too tall it will create a lip above the foam. To check
set your foam and wood next to each other on the
table and see how they match up.
This is the most difficult step. I found that a table saw
works pretty well, but it is still difficult to cut squarely.
You can cut it with a utility knife blade and then dress
up the edge with a sanding block and wood guide.
(see pictures) Test fit often to make sure you don't
take too much off.
Glue

Drill holes for fastening system
Drill the holes where they line up with your fastening
system. For me this was every 4 inches. I then test fit
it to make sure. Also consider insetting the holes for
the bolts so they don't stick up into your stock.
Screw wood frame together
Clamp and screw the frame together making sure it is
all still square. I used 1-1/4in wood screws, but
whatever works.
After everything fits nicely, fasten the frame to your
CNC table and mask the bottom edge where the
foam and wood meet. Apply a very thin bead of
Gorilla glue to the edge of the foam and spread it out.
Spray the frame with a little bit of water to activate the
gorilla glue. Then slide the foam into the frame and
set weights on it. You might also consider placing thin
spacers under the frame just to make sure the foam
makes it all the way to the bottom.

Simple CNC Vacuum Table: Page 3

Simple CNC Vacuum Table: Page 4
Step 3: Cut
Cut Top of foam
Cutting this foam is a breeze. The toughest thing is
flipping the board over to do the other side. I made
the origin on one of my bolts because this was an
easy reference point. If it is not lined-up very well,
don't worry about it because it doesn't matter in the
long run.
Simple CNC Vacuum Table: Page 5
Bit = 1/4in 2 flute straight. Feedrate = 80-100ipm.
Spindle = 15,000rpm. Stepdown = 1/4in
Cut the bottom
When you cut the bottom you will want to cut a
channel through the wood frame. Make sure you slow
down your cutting when you cut wood.
Step 4: Add Bracket
Cut
I used a 1/8in endmill for cutting the bracket. I made a
rooky mistake when I left the feedrate at 80ipm but I
got lucky and the machine cut it fine. Always check
your feedrates. I included a dxf of the bracket as well
as including it in the Fusion 360 file. For the dxf, the
semi-circle is half the thickness of the plywood and
the rectangle at the bottom cuts all the way through.
Test fit your PVC pipe onto the bracket to make sure
it still sits flat with the pipe installed.
Simple CNC Vacuum Table: Page 6
Drill and screw
Line the bracket up with the channel on the front of
the frame and drill holes for your screws. Screw it on!
Add the tube
My tube is currently just friction fit in the bracket. It
needs to be able to support the weight of the vacuum
hose. If this doesn't work, Gorilla glue works great,
just use it sparingly.
Simple CNC Vacuum Table: Page 7
Step 5: Use

Using this vacuum table is very easy. You simply lay your material on, block any unused quadrants with extra
foam or wood cut to size, and turn your vacuum on.

If you don't build the valve, leaving a small gap around the edges makes it easier on your vacuum.

In the picture you can see that I cut some Adams foam board. I am cutting a Flite Test Simple Cub RC airplane. It
works great for this kind of stuff.

Simple CNC Vacuum Table: Page 8

Step 6: Vacuum Adjustment Valve

Credit to the comments for this idea. When you run
the vacuum table with the vacuum directly hooked up,
it tends to put undue stress on the vacuum so I
wanted to make a valve to adjust the airflow. The idea
is pretty simple but very effective. It has a sliding tube
that covers and uncovers a slot in the vacuum tube.
All it needs is a straight fitting the size for the tube.
Cutting Fitting
You need to cut the fitting so it fits around the tube
without hitting the table. Mark the fitting with a sharpie I try to allow just enough pressure to keep my
and cut with a handsaw or Dremel.
Sand Inside Lip
The fitting comes with a lip inside to make the tube
stop half-way. I was able to sand it off really easily
with a Dremel. It sands so easily you could probably
do it by hand. Make sure you sand enough off to
make it slide easily on the tube.
Cut Slot
Use a large drill bit to start the hole and touch up with
the Dremel or sand paper.
Use
material securely down but no more than that. There
might be a tiny bit of leakage around the fitting so you
might consider skipping this if your vacuum isn't very
big.

Simple CNC Vacuum Table: Page 9

Step 7: Final Thoughts

This project is 100% opensource. If you have suggestions, please comment and let me know. Future ideas include
better plugs for the quadrants, and maybe even changing the grid pattern for improved air flow.

Thanks for reading this instructable. It has really helped me to organize my ideas and I hope it will inspire you to
make your own vacuum table.

Nice job on the vacuum table. I like the use of the foam as a sacrificial element. What are you
using to cut the foam board for the airplane parts?
Thanks. I have been using 0.8mm endmills that I got from Aliexpress. They cut great but do leave a
little bit of a rough edge. I have also thought about trying a needle foam cutter like this one.
https://www.instructables.com/id/CNC-Needle-Cutter/
Thanks for the info.

That's a project that took a lot of thought. Thank you!

"Future ideas include a valve for the vacuum" ... Make your valve by cutting a slot in that vacuum
input pipe with a sliding ring fitted around it. Slid the ring to create more or less of a vacuum leak.

Simple CNC Vacuum Table: Page 10

Thanks for the suggestion. I was thinking about something along those lines myself. My only worry
is that it wouldn't be airtight enough when you need it to be, but I'll give it a try and if it works, I'll
post it in the instructable.
Thank you for this timely Instructable project. I have built a DIY CNC Router and now I'm interested
in making foam board airplanes like those from Flite Test.
Very nice. :) How do you like the Rascal? I looked at the webpage & see it is open source.

Thanks. The Rascal is a great machine. Like you said, it is open source so it does take some more
time and research to build. It is very comparable to the x-carve in terms of capability.
This vacuum table turned out great :)

Thanks for the encouragement. This is my first instructable and I am looking forward to writing
more.

Simple CNC Vacuum Table: Page 11