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  1. #1
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    Lightbulb Custom Made 3D printed vacuum pucks

    So I recently acquired a 3D printer of my own, and have made my own vacuum pucks for securing panels to the workbench. The idea came from these :
    Podz™ Vacuum Clamping Jigs for Benchtop Use


    A bit of googling resulted in me selecting 6mm round EPDM Sponge for the gaskets. Using foam was no good as you can't get a good seal - they leak air. Using solid rubber was no good either as any I found wasn't flexible/compressible enough. EPDM Sponge seemed to be what commercial ones were using and I located some on eBay for a resonable price. 6mm diam, 15m long for $16.40.
    Once it arrived I knew I had the right product - solid, so no leaking, but nice and compressible so it will make a good seal.

    20211008_101842.jpg


    Fusion360 was used for all the CAD modelling.
    Fusion360 CAD-2.JPGFusion360 CAD-1.JPG
    First I designed and printed a test article with various size/depth/shape trenches, to determine the right size for the EPDM Sponge to get it just above the surface at rest, and compress down into it when under vacuum pressure. Ultimately I went with 6mm wide x 5mm deep square trench.

    20211008_101414.jpg20211008_101541.jpg


    Next step was to figure out the optimum radius for inner and outer curves on bends so there was no gap around the gaskets when they moulded around a corner. This test article had 4x 3mm inner radius' with varying outer radius'. I settled on 3mm inner radius with 10mm outer radius.
    20211008_101627.jpg20211008_101703.jpg


    For the pucks, I had 1/8BSP fittings that take 8mm vacuum hose. The pucks are designed so that the vacuum enters the puck, and travels around a 6mm inner printed pipe, with 4x 4mm holes extending up and down. Once printed I used a 1/8BSP tap to adjust the printed thread, and then screwed in the fittings with thread tape on them.
    20211008_101739.jpg20211008_101726.jpg


    After a bit of trial and error, the EPDM Sponge was then cut to lengths to allow about 5mm overlap. When pressed into the retaining trench in the puck, it gets squashed back a bit to line up the ends but the pressure of the overlap ends against each other means there's no gap for the vacuum to escape, and the ends don't need to be glued together. Once in place they end up raised above the surface by just over 1mm. I found this is enough to get a good seal between panel and bench, but not so much that the puck can't get sucked down flat onto the bench.
    20211008_102012.jpg20211008_101757.jpg


    So once the air line is fitted, you just sit the puck on the bench, put a panel to be sanded or whatever on top, a light press with your finger and the vacuum sucks the puck down to the bench, and also the timber panel down onto the puck/s.
    Now you can us a Random Orbital Sander on the timber without any G-clamps getting in the way.
    You can't see it on the picture below, but there is a foam gasket on top, and bottom of the puck, and the 4x vacuum holes go through top to bottom, to enable vacuum above and below the pucks.
    20211008_102112.jpg20211008_104710.jpg


    Each puck cost me ~ $3.50ish. Print time for 4x pucks was about 24 hours.

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  3. #2
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    Interesting but I still wonder if it's really needed?

    I usually use a piece of soft dimpled foam kitchen drawer liner on the bench top and put the workpieces on top of that and they don't go anywhere when using a ROS.

  4. #3
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    Hey Bob.
    You raise an interesting point - Is it really needed? I guess everyone will have their own perspectives on that one.

    Well, I would answer that by saying when I built my vacuum press setup I invested many, many hours researching and building, and ultimately made a setup that could do what I needed to right then, along with anything I could come up with in the future.

    Did I need to spend those $$ and make it as fancy?
    Right then, no. At that time I expected I'd use it maybe once a month.

    Several years down the track I can tell you that it gets used 5-6 times a week. Having built more than I needed, I've ended up finding uses for it that I never thought I'd even need, but have proven to be awesome in making regular tasks just that much easier.
    So do I 'need' to make vacuum pods? No. Once they get regular use, will I be glad I spent the time designing and making them - I expect so.

    To each their own. If $2 worth of non-slip matting meets your needs, great!
    Some people think a $250 Bunnings thicknesser is amazing - personally I like my Felder thicknesser, and am happier for having access to it. Is vacuum clamping any better than non-slip matting? If from your perspective the answer is No, then you've saved yourself $$.

    Nasa developed a pen that can write in space - The Russians used a pencil. As long as whatever tool they use does the job they want, then that's the right tool for them.

    Once more supplies arrive from OS, I'll build a manifold and then test these properly in the way I have in my head that they will work. This will include routing panels as well as sanding. I don't know if I'd be game to use a router on a panel with only non-slip matting, but vacuum pods will beat having to move G-clamps all the time.

    I'll let you know in a few months time if they get regular use.

  5. #4
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    Nice job. I seem to remember someone in the Felder owners group using simple vacuum clamps to process multiple small parts - slap the part down, activate the suction, drill/domino/whatever, unsuck, repeat. Seemed like an excellent way to improve the workflow for a repetitive process.

    I may try something similar - particularly for holding smaller pieces when plunging with the domino. They're generally a pain to hold down.

    Are you going to put your files on thingiverse?

  6. #5
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    Quote Originally Posted by TimberNut View Post
    Nasa developed a pen that can write in space - The Russians used a pencil.
    I'm going to be the 'well ahktually' guy here - the story of space pen vs pencil is a myth. The Fisher space pen was developed by a private company with their own funds - early on both astronauts and cosmonauts used pencils. The Fisher pen was superior because it didn't have any issues with bits of 'pencil lead' flaking off or tips being broken and floating around or be made from a relatively combustible material.

    Now that I've sucked all the joy out of life, carry on, as you were.

  7. #6
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    I actually think the true story but enduring popularity of the myth is how easily a nice anecdote can spread when it feeds into inherent biases or is nice to believe.

    Don't get me started on the one about the woman who sued McDonalds because her coffee was too hot and got a million bucks...

  8. #7
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    Quote Originally Posted by TimberNut View Post
    This will include routing panels as well as sanding. I don't know if I'd be game to use a router on a panel with only non-slip matting, but vacuum pods will beat having to move G-clamps all the time.
    Agree about the routing - especially moving clamps.

    I've got a job where I though something like that would be handy but teh workpieces are weathered/cracked pickets from a fence - I doubt they will hold vacuum.
    Id also need to get a new bench top or at least resurface it as its pretty beat up.

  9. #8
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    Hey Bob, as my dad always says - 'There's many ways to skin a cat'... not that I know why you would want to, but hey.... I'm confident they'll work for routing panels. Sanding too, seeing as I have them now. As to what other tasks they will get used for, I'm sure things will pop up. There'll be lots of times when non-slip mat is the better/quicker solution, but these will be just another tool in the toolbox. Time will tell I guess, just how many scenarios where they are the quickest, easiest solution.

    Hey Bern, I've got plans to design a vacuum grid panel (about 200x200 with lots of holes to make holding lots of small stuff in place easy without clamps all at the same time. Now that the 'small' ones are done, and the theory is sound, I'll focus on designing the larger panel.
    Re thingiverse - sorry, but no, I won't be doing that. Now that I've designed them, printed them, and proved they work, I plan on selling them, so won't be making the CAD designs freely available. If I don't get many sales, in future I might give the files away for free, but not right now.

  10. #9
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    Quote Originally Posted by Cgcc View Post
    Don't get me started on the one about the woman who sued McDonalds because her coffee was too hot and got a million bucks...
    I believe that was a Seinfeld episode.



    What do you actually use a vacuum source for these? shop vac... Hand pump... small vac pump?

  11. #10
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    I purchased a second hand Festool vac sys a few years ago on a whim. It’s essentially a vacuum clamping system and you can buy various pods of different shapes. It rotates, tilts to various angles and has a quick release foot pad.

    I was expecting it to be a handy addition to my work flow but it absolutely exceeded my expectations. Having the ability to hold something down and use a router without clamps getting in the way is really nice. Where it really stood out for me was sanding over 30 serving boards. It saved me a lot time and actually made sanding enjoyable.

    I’ve used those rubber mats but I found sanding or routing small sized work pieces it would still move and vibrate.

    Each to their own but for the price you paid for the setup I reckon you’ve done really well.

  12. #11
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    Quote Originally Posted by havabeer69 View Post
    What do you actually use a vacuum source for these? shop vac... Hand pump... small vac pump?
    I use an auto cycling vacuum system that I built - details here:
    Auto-cycling vacuum pump for vaccum bagging veneers and vacuum clamping.

    There are many sources of vacuum pressure available from 2nd hand refrigerator pumps, to venturi valves connected to an air compressor, to more elaborate systems like mine, but anything that can pull a decent vacuum will work.
    My system can be set to either auto-cycle on/off to keep vacuum at a given pressure, or set to stay on constantly. For these I set it to constant vacuum, and use a foot pedal to release vacuum as required.

    Andy - I'm not surprised you've found it more useful than you first thought! Vacuum clamping is a real game-changer in certain applications (they're not only useful for pressing veneers to substrates). Once you've got access to a decent vacuum source that allows you to regulate pressure, it's amazing how many situations become just that much easier.
    When I built my vacuum press I always intended to make pucks like these, but have only recently acquired the 3D printer and CAD skills required. So now they're done and work exactly as I'd anticipated. I'll be making a manifold for them shortly which will allow me to control vacuum level to each puck individually. I just have to wait for some more parts to arrive from OS, and then I'll design and print it. I'm not sure how often I'll need to differentiate vacuum pressure between pucks, but you never know! Regardless, it'll allow me to send vacuum to each/any/all rapidly, so will just extend the flexibility of the setup.

    I've also got some bearings coming, and have plans to develop and print a vacuum clamp for the lathe too, so I should have that sorted within a month or so. I know how it will work, but I just need a couple of bearings before I can get that underway. So stay tuned for that one!
    I'll post details of that, and the manifold when they are made.

  13. #12
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    Vacuum clamping is a real sleeper here in Oz.
    I did a veneering job in Canada in 93 using a mates vac press set up.
    Also turning with a vac chuck there a few years back.
    Made myself a vac chuck here from an old Al scuba bottle.
    Only did a rough gasket so I might remachine the lip and try that EPDM sponge.
    H.
    Jimcracks for the rich and/or wealthy. (aka GKB '88)

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