Honeycomb Support and Allignment
Instruction
I was annoyed by having to manually align the honeycomb each time. Although I did find some 3D prints I could not find any free laser cut files. I also thought it was annoying to remove the legs all the time so I combined the alignment with 3 different levels for the honeycomb.
I used the 500x500mm honeycomb from xtool, but should work for any other honeycombs with same dimensions. Or you can adjust the dimensions in F360.
If you have a thick object simply move the honeycomb one level down or remove it. The top layer of the honeycomb makes it at height 0, this means the height is as it would be on a regular surface (flat on the table without honeycomb). This prevents the honeycomb from taking up 20 mm of your laser height as well!
The alignment places the honeycomb in the middle of the laser, this makes sure you can make full use of the area. The other benefit is that all the pieces are the same for the different leg positions.
If you want to use a thicker or thinner material let me know I can easily adjust the files. Or I can share the Fusion360 Files (material thickness is changed by a parameter!). Fusion360 project can be found at:
https://a360.co/3RQLTNm (if you prefer other format please met me know).
The Lightburn and XCS files are for 3.6mm. The DXF files are assigned with the material thickness in front of the part name (eg 6mm Place holder >> is the place holder for material 6mm thick).
Any feedback or suggestions are welcome, since this is my first project/how to on Xtool.
*EDIT 06-01-2024: added design for 6mm thick material added the fusion 360 project and minor changes to the explanation.
* added 3mm as well
and just to be sure the version without thickness in front of it is for 3.6mm
Cut the pieces all the pieces.
If you use the dxf files:
4x Bottom HC Placeholder bottom [Green] (if you want to attach to spoilbord/table otherwise replace with HC Placeholder)
8x HC Placeholder [Pink] (holds the honeycomb in place)
8x Level [Orange](this is where the honecomb lays on)
8x Vertical Support [Brown]
I used a vertical support for the height, if you want more stability cut the pieces with a missing corner more off then to stack them (no image of this setup yet I desired I might add).
Also if you don't want to use the different levels only print the pieces that keep the honneycomb in place (at least the Pink ones from step 3). The green once keeps the honneycomb in place and can be screwed to a spoilbord or table (if that is what you want), if you dont want to you can replace the green with pink aswell.
I used on my 20W laser 40mm/s @ 100% power, and 5 passes.
You do have to note your kerf settings! Mine are at 0.07. otherwise you might need some light sanding paper
The different pieces are all the same, however for assembly the Bottom Left and Top Right corner are the same, the Top Left and Bottom right are in mirror image. Simply flip the pieces upside down to get them in the right orientation!
I sometime slide the honeycomb in from the front of the machine, this is only possible if you keep the vertical support (orange) aligned (or parallel) with the y axis.
Place them on the legs. If you dot screw them to the table they might turn freely, the Honeycomb should fit in snugly and all corners should connect to the honeycomb. If the honeycomb dosnt fit check if you honeycomb is square (mine wasn't exactly).
If you like this project and want to make if even more easy for yourself to use absolute coordinates get a sheet of material the size of the honeycomb (or any dimension you like) and place it flat to the side of the honeycomb and you can still see the measurement stripes.
Now cut as close to the limits as you machine can handle or maybe 5mm from the edges (15mm to 20mm if you use cross for framing, this also give issues with me and the limit switched). For some reason mine give limit warning if I try to cut at distance 0 after homing…
You can leave, or place back, this edge on the honeycomb as home position guide. Since the honeycomb has fixed position now place the edge back and you now know where 0! You can use this for and templates you have (don't cut near the edge but the utilities you use).
(if this is to vague leave a comment I will write a better How To…)