Stable base
The base keeps the X axis aligned so the cutting path can be repeated with less variation.
Axes
Movement built around X, Y, and Z
The X axis works as the base. The Y axis moves across it, and the Z axis raises or lowers the cutting tool. This structure is enough to position the cutter, contact the foam, move through the path, and lift away when needed.
The design uses threaded rods, stepper motors, structural plates, and a cutting tip assembled into a small router for expanded polyethylene. The mechanism favors visibility over compactness: each axis can be observed, adjusted, and related back to the driver software.
Mechanical role
How the frame supports the control system
Guided movement
Threaded rods and motor rotation convert electrical steps into linear displacement.
Tool positioning
The Z axis separates cutting movement from travel movement, reducing unwanted contact with the material.
Build references
Mechanical parts
X axis
Base movement structure.
Y side
Side view of the Y axis assembly.
Cutting tip
Tool contact area for foam cutting.
Used parts
Main mechanical elements used in the build.
Threaded rod
Linear motion component prepared for the axes.
Stepper motor
Motor reference for controlled mechanical movement.
Motion reference
Animated view of the router concept.
Relay
Auxiliary component reference from the project.
Rod dimensions
Dimensional reference for mechanical planning.