Hi folks,

Mark, I could put some solar panels on CarBEN EV eventually, but initially I will be concentrating on the aerodynamics and the myriad of construction details. You need at least 4-5X more surface area than CarBEN has and the angle to the sun is an serious issue as well. I think it would be best to put the solar panels on my house, and charge it while it sits in the driveway.

dugd1013, the foam sections I will be cutting *will be* the chassis core, with fiberglass skins on the inside and the outside. There will probably be a front steel subframe, but the fiberglass/foam composite sandwich will be the main chassis.

The battery pack is in the floor, and it is about 56kWh; using 768 EiG lithium cells. Each cell is 3/8" thick x 5 1/2" x 10 1/2", and it should weigh about 900 pounds. There will be twin direct drive motors, each driving one front wheel through a driveshaft. It will have 5 seats, in an unconventional arrangement (driver in the center and the passenger seats staggered behind -- see the drawing on my blog.

 

I have questions about using the PhlatPrinter III:

How do I speed up the jogging speed?

To cut a nominal 2" x 2' x 8' sheet of foam, do I set the limits to that dimension precisely, of do I set it to about the 1 1/2" shy of each of the ends and about 1/4" shy of either side (due to the tongue and groove there)? Or do I just set up the cut pieces to be inside these margins?

With the stock bit having cutting teeth on only part of the shank, how do I set the cuts to go in 2 depth passes?

Do I have to "tell" it to always raise the Z-height to clear the foam between cuts, or will it do this automatically? Where is this set?

I need to get some rollers to support the foam when it is sticking out 4-8' -- any ideas on where to buy these?

 

Neil, I never cut 2" but I think that you can't do it with the stock bit. Once the part without the cutting edge is in the foam it most likely will heat and melt the foam. I'm not sure that it will do it but that what happens with the smaller bits. Try it out and you'll see. If it will melt the foam you'll have two options. 1) Buy a new router and mount it instead of the flex shaft. A router can take a 1/4" bit and they come in 2" length if you look for it. 2) Look for a bit with a 1/8" shank but a bigger cutting edge. You'll be cutting with the multipass and it will work out fine.

As I've said before, you can't go, on the x axis, all the way to the front or back. I said that you'll have to leave about 1.25" more or less and this still stands. Measure it and you'll know how much it is exactly. Once you have that measurement you'll subtract it from your total foam length and the result you will put in the parameter box in the SketchUCam in SU, if that is what you use, if you use another program to generate your g-code you'll have to follow the instruction in that program.

On the y axis you can go as close to the edge as you want. I have barely an 1/8" of material left when I cut. That's how close I go to the edge.

If you use SketchUCam you don't have to worry about the z height, it does it automatically and I'm sure that other programs do it too. Generate the g-code and look at it in a backplot program. You'll see there if it goes up for the travel or not.

Can you use these for rollers? http://www.amazon.com/gp/product/B001DT ... CKZMZ9XTDJ

 

Thanks -- I've confirmed the 1 1/4" minimum at the ends -- I'll use 1 1/2" on the layout to give a little wiggle room.

I'm hoping to be able to figure out how to cut the depth in 2 passes -- one at 1" deep and the second at another 3/4" deep -- about the maximum length of the stock bit.

Here's a real pretty sight:





I used this excellent cleanup plugin in SketchUp:

http://forums.sketchucation.com/viewtopic.php?f=323&t=22920

You have to register and sign in to see it, and you'll need to download and install the TT_Lib2 files, but it seems to be helpful. Though I still need to draw at least one line in SU to get a face, and on a few, there are some small gaps. I thought that you needed to have inside cuts open, but not so.

What does the Plunge Tool do?

I don't think I need tabs as the last 1/8"-3/16" at the bottom surface will not be cut.

I may be all set to generate the g-code! I wish we could figure out the 2-depth passes...

Edit: I almost missed the rollers you linked to! Those are precisely what I need -- I've ordered four!

What is SketchUcam?

 

Neil, let me make sure, you are using SU, right? If yes, than the plunge tool is for drilling holes. As for the two passes, check the 'generate multipass' option in the parameter box and set the depth of the cut you want in the box bellow it. And if you'll use the 4mm bit I've mentioned a few post back you'll be able to make a full 2" cut.

 

Yes, I am using SketchUp both the model the car, and then later to generate the g-code. I am using SU in tandem with DataCAD, which can XRef and export SU files. And I'm using the CNC USB program that ships with the PhlatPrinter III.

Which program has the 'generate multipass' option?

If I find a longer bit, how do I then adjust the outside / inside cut tools for the larger diameter?

What is SketchUcam?

Thanks again Yoram, for your help.

 

Don't mention, I just want a ride in that thing!

 

I have now laid out 4 sheets of foam with (almost) 7 sections:


7 sections finished and laid out on 4 (2'x8') sheets of foam; and the 8th section is started! Only 77.5 sections to go...

Section F0 is on the right end, and it is at the highest point of the roof. F1 through F7 are each ~2" forward of the previous. You can see the "ball and socket" joints, and the 1/2" diameter alignment holes. The support rollers come on Thursday so I will probably make the first foam cuts next weekend!

The bottom piece of F7 is going onto the next sheet of foam, so these four sheets will build just less than 14" of the length of the CarBEN EV. They cost about $36... Of course the fiberglass will be more.

My brother Nathan, who works for UPS suggested these omnidirectional rollers:



...and I was going to try and use them, but the rollers I am getting are ready to go:


(click on image for link)

I've ordered four of them, which should do the trick.

I will be making an alignment jig, once I figure out how to set up the USB CNC program. I am leaving 1.5" at each short edge and .375" on each long edge -- the friction rollers need 1.25" minimum to keep a "grip" on the sheet and there is a .25" tongue/groove on the long edges.

Jigsaw puzzle joint makes sense to me. The slowest part of this process is that I have to "sum" the two adjacent sections -- they are cut starting at the high point of the roof, and the ones I am working on are cut "looking" forward of this. I then cut the next section, and layout the inside profile -- and then I copy the entire second section over the first one. I then erase all the lines on the inside; keeping the outer-most lines only. This makes the stepped form will always be larger than the finished shape, and I will only have to *remove* the steps to get the actual form of the car.

This was the major lesson of making the quarter scale model -- I had lots of voids wherever the shape "grew" from the previous section. And on the full size one I am now doing, it is the *inside* surfaces that need to be taken into account!

 

Is it possible to set the cutting depth to ~1% so I can cut the part number on to each piece?

Also, do I set the 2 stage cuts of the main cuts to 50% in SketchUp with one of the plugins, or is this done in the CNC USB program?

Is the Safe Area tool (in SU) preset size only, or can it be customized? When I load the DOW foam Material file in CNC USB and change the X size to 96.00, nothing seems to change in the display. Will the cutting be limited to this area?

 

I generated the g-code in SU, and when I try to import it into CNC USB program, I get an error code:



How do I debug this?

Edit: is the flattened arc on the left the issue?


The other side (and all the others) are all arcs, but this one is a chord...

 

I will try this process again -- I did use the Clean Up plugin *after* doing the Phlat Tools but before making the g-code. Hopefully it goes through okay, or I am up a creek...

Or, maybe I have to do the Phlat Tools in the Windows version of SketchUp? I am running Fusion and WinXP on the iMac, so if this is what is needed to get it to work, I'm fine with that.

 

Neil, to write a number on the foam write it on it SU where you it and then use the center line tool to mark it. Before you mark it enter the depth of the cut. In your case just enter the digit 1 (one) end press enter. You'll see it in the right bottom corner coming up like this ' 1% '.

 

Okay, I tried again to export th g-code in SketchUp 8 for Mac, and it gives me another error hen I try to import the g-code into CNC USB...

I am trying to run v7 in WinXP but the PhlatscripT tools do not show up there -- how do I get out of this conundrum? How can I get my g-code to work?

Help, please!

 

Okay, here's the contents of one of the CNC files:

%
(Generated by PhlatscripT {0.924})
(File: Sheet F1 take umpteen.skp)
(Bit diameter: 0.1250")
(Feed rate: 100.0000")
(Material Thickness: 0.2500")
(Material length: 22.0000" X width: 42.0000")
(Overhead Gantry: false)
(www.PhlatBoyz.com)
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(move x= 59.561575 GT max of 42.0)
Y0.7813 Z-0.3500
(move x= 54.249055 GT max of 42.0)
Y0.4395 Z-0.3500
(move x= 53.897611 GT max of 42.0)
Y0.4372 Z-0.3500
(move x= 53.061832 GT max of 42.0)
Y0.4317 Z-0.3500
(move x= 52.110016 GT max of 42.0)
Y0.4255 Z-0.3500
X41.6855 Y0.3568 Z-0.3500
X41.4513 Y0.3553 Z-0.3500
X35.2902 Y0.3147 Z-0.3500
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X25.9218 Y0.3553 Z-0.3500
X25.6876 Y0.3568 Z-0.3500
X15.2631 Y0.4255 Z-0.3500
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X6.8727 Y0.9284 Z-0.3500
X6.6553 Y1.0019 Z-0.3500
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X5.1325 Y1.6876 Z-0.3500
X4.9523 Y1.8296 Z-0.3500
X4.3823 Y2.2787 Z-0.3500
X3.7707 Y3.0689 Z-0.3500
X3.3813 Y3.6869 Z-0.3500
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X2.9450 Y5.0054 Z-0.3500
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X2.2219 Y10.1257 Z-0.3500
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X1.5250 Y18.8998 Z-0.3500
X1.4980 Y19.5639 Z-0.3500
X1.4377 Y21.8355 Z-0.3500
(move y= 22.500734 GT max of 22.0)
Y22.0000 Z-0.3500
(move y= 23.843605 GT max of 22.0)
X1.5011 Y22.0000 Z-0.3500
(move y= 22.075295 GT max of 22.0)
X3.2694 Y22.0000 Z-0.3500
G17 G2 X3.2836 Y22.0593 Z-0.3500 R0.1875
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X3.3074 Y22.0192 Z-0.3500 R0.1875
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X3.2827 Y21.8283 Z-0.3500 R0.1875
G17 G3 X3.0100 Y21.3503 Z-0.3500 R1.5625
X2.9350 Y20.8131 Z-0.3500 R1.5625
X3.0646 Y20.2865 Z-0.3500 R1.5625
X3.3802 Y19.8454 Z-0.3500 R1.5625
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X4.9021 Y19.5529 Z-0.3500 R1.5625
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X5.7290 Y21.3503 Z-0.3500 R1.5625
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G17 G2 X5.4470 Y21.8407 Z-0.3500 R0.1875
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X5.4423 Y22.0400 Z-0.3500 R0.1875
X5.4554 Y22.0593 Z-0.3500 R0.1875
X5.4696 Y22.0753 Z-0.3500 R0.1875
(move y= 23.843898 GT max of 22.0)
G1 X7.2382 Y22.0000 Z-0.3500
X7.8434 Y10.5008 Z-0.3500
G0 Z0.1250
X8.6963 Y9.9764 Z0.1250
G1 Z-0.3500 F100
G17 G2 X8.6465 Y10.0412 Z-0.3500 R0.3125
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G0 Z0.1250
X9.2377 Y11.0098 Z0.1250
G1 Z-0.3500 F100
G17 G2 X9.0682 Y11.1500 Z-0.3500 R0.5625
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G1 X9.0481 Y12.8171 Z-0.3500
G17 G2 X9.3094 Y13.2102 Z-0.3500 R6.7686
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X12.8587 Y15.7584 Z-0.3500 R6.7686
X13.2866 Y15.8727 Z-0.3500 R6.7686
G1 X13.4442 Y15.9141 Z-0.3500
X13.7459 Y15.9613 Z-0.3500
X14.0550 Y16.0117 Z-0.3500
X14.3714 Y16.0344 Z-0.3500
X14.6745 Y16.0550 Z-0.3500
X15.0042 Y16.0512 Z-0.3500
X15.2936 Y16.0438 Z-0.3500
X15.4767 Y16.0519 Z-0.3500
X15.9114 Y16.0710 Z-0.3500
X16.3087 Y16.0777 Z-0.3500
X17.3664 Y16.0955 Z-0.3500
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X18.6471 Y16.0639 Z-0.3500
X18.8653 Y15.9976 Z-0.3500
X18.9283 Y16.1222 Z-0.3500
X30.8389 Y16.6250 Z-0.3500
X31.9727 Y16.6730 Z-0.3500
X32.9817 Y16.7089 Z-0.3500
X35.8086 Y16.8095 Z-0.3500
(move x= 42.613604 GT max of 42.0)
X42.0000 Y16.8896 Z-0.3500
(move x= 42.936810 GT max of 42.0)
Y17.0005 Z-0.3500
(move x= 43.295213 GT max of 42.0)
Y17.0814 Z-0.3500
(move x= 44.092529 GT max of 42.0)
Y16.8615 Z-0.3500
(move x= 44.148131 GT max of 42.0)
Y16.8511 Z-0.3500
(move x= 45.435777 GT max of 42.0)
Y14.7620 Z-0.3500
G17 G2 X45.9479 Y14.9524 Z-0.3500 R1.5625
X46.5576 Y14.9301 Z-0.3500 R1.5625
X47.1124 Y14.6761 Z-0.3500 R1.5625
X47.5277 Y14.2291 Z-0.3500 R1.5625
X47.7404 Y13.6572 Z-0.3500 R1.5625
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X45.2807 Y12.1412 Z-0.3500 R1.5625
X44.9087 Y12.5414 Z-0.3500 R1.5625
(move x= 42.819697 GT max of 42.0)
G1 X42.0000 Y11.2538 Z-0.3500
X33.2425 Y13.9909 Z-0.3500
G17 G3 X32.9762 Y14.0636 Z-0.3500 R12.0625
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G1 X27.1695 Y14.4540 Z-0.3500
G17 G2 X27.1020 Y14.4582 Z-0.3500 R0.5625
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G1 X26.5606 Y15.5735 Z-0.3500
X23.5685 Y15.4472 Z-0.3500
X16.5330 Y15.2606 Z-0.3500
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X15.8035 Y14.1246 Z-0.3500 R0.5625
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G1 X15.5661 Y14.1160 Z-0.3500
X14.0815 Y14.1347 Z-0.3500
X13.6785 Y14.0689 Z-0.3500
X13.2876 Y13.9665 Z-0.3500
X12.9142 Y13.8294 Z-0.3500
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X12.2551 Y13.4751 Z-0.3500
X12.0734 Y13.3436 Z-0.3500
X11.9193 Y13.2289 Z-0.3500
X11.6353 Y12.9716 Z-0.3500
X11.3776 Y12.6886 Z-0.3500
X11.1458 Y12.3795 Z-0.3500
X10.9554 Y12.0620 Z-0.3500
X10.8050 Y11.7295 Z-0.3500
X10.0521 Y11.5976 Z-0.3500
G17 G2 X10.0662 Y11.4485 Z-0.3500 R0.5625
X10.0015 Y11.2382 Z-0.3500 R0.5625
X9.8613 Y11.0687 Z-0.3500 R0.5625
X9.6669 Y10.9658 Z-0.3500 R0.5625
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X9.2377 Y11.0098 Z-0.3500 R0.5625
G0 Z0.1250
X11.3800 Y9.0823 Z0.1250
G1 Z-0.3500 F100
G17 G2 X11.1588 Y9.6509 Z-0.3500 R1.5625
X11.1721 Y10.2609 Z-0.3500 R1.5625
X11.4179 Y10.8194 Z-0.3500 R1.5625
X11.8586 Y11.2413 Z-0.3500 R1.5625
X12.4273 Y11.4625 Z-0.3500 R1.5625
X13.0372 Y11.4491 Z-0.3500 R1.5625
X13.5374 Y11.2291 Z-0.3500 R1.5625
G1 X14.9450 Y13.2393 Z-0.3500
X15.0011 Y13.2465 Z-0.3500
X15.8099 Y13.4193 Z-0.3500
X16.1629 Y13.3176 Z-0.3500
X16.4791 Y13.1880 Z-0.3500
X23.2678 Y12.7102 Z-0.3500
X26.0840 Y12.4445 Z-0.3500
X27.0892 Y12.3496 Z-0.3500
X28.2183 Y12.2354 Z-0.3500
X30.3911 Y12.0160 Z-0.3500
X32.2734 Y11.8258 Z-0.3500
X40.0797 Y11.0370 Z-0.3500
X40.1330 Y10.9087 Z-0.3500
X40.3564 Y10.9625 Z-0.3500
X40.4043 Y11.0122 Z-0.3500
X41.6216 Y10.9202 Z-0.3500
X41.6365 Y10.9192 Z-0.3500
(move x= 42.691503 GT max of 42.0)
X42.0000 Y10.8395 Z-0.3500
(move x= 43.087745 GT max of 42.0)
Y10.8096 Z-0.3500
(move x= 43.520599 GT max of 42.0)
Y10.7651 Z-0.3500
(move x= 43.702886 GT max of 42.0)
Y10.7463 Z-0.3500
(move x= 43.992272 GT max of 42.0)
Y10.7368 Z-0.3500
(move x= 44.321657 GT max of 42.0)
Y10.7213 Z-0.3500
(move x= 44.622993 GT max of 42.0)
Y10.6830 Z-0.3500
(move x= 44.937557 GT max of 42.0)
Y10.6418 Z-0.3500
(move x= 45.243118 GT max of 42.0)
Y10.5735 Z-0.3500
(move x= 45.541569 GT max of 42.0)
Y10.5087 Z-0.3500
(move x= 45.696531 GT max of 42.0)
Y10.4582 Z-0.3500
G17 G2 X46.1170 Y10.3190 Z-0.3500 R6.7686
X46.5292 Y10.1518 Z-0.3500 R6.7686
X46.9295 Y9.9579 Z-0.3500 R6.7686
X47.3162 Y9.7381 Z-0.3500 R6.7686
X47.6877 Y9.4934 Z-0.3500 R6.7686
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X49.2623 Y7.9363 Z-0.3500 R6.7686
X49.5112 Y7.5677 Z-0.3500 R6.7686
X49.7491 Y7.1599 Z-0.3500 R6.7686
(move x= 49.463209 GT max of 42.0)
G1 X42.0000 Y6.3744 Z-0.3500
G17 G2 X49.5968 Y6.2934 Z-0.3500 R0.5625
X49.7268 Y6.1160 Z-0.3500 R0.5625
X49.7791 Y5.9024 Z-0.3500 R0.5625
X49.7457 Y5.6850 Z-0.3500 R0.5625
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X48.6527 Y5.8532 Z-0.3500 R0.5625
X48.6755 Y6.0012 Z-0.3500 R0.5625
(move x= 47.940422 GT max of 42.0)
G1 X42.0000 Y6.1749 Z-0.3500
G17 G3 X47.7717 Y6.5613 Z-0.3500 R4.2029
X47.5836 Y6.9001 Z-0.3500 R4.2029
X47.3642 Y7.2195 Z-0.3500 R4.2029
X47.1155 Y7.5167 Z-0.3500 R4.2029
X46.8397 Y7.7888 Z-0.3500 R4.2029
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X46.2171 Y8.2488 Z-0.3500 R4.2029
X45.8759 Y8.4324 Z-0.3500 R4.2029
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X45.1490 Y8.6986 Z-0.3500 R4.2029
X44.7699 Y8.7788 Z-0.3500 R4.2029
X44.3844 Y8.8227 Z-0.3500 R4.2029
(move x= 43.821725 GT max of 42.0)
G1 X42.0000 Y8.8413 Z-0.3500
(move x= 43.285482 GT max of 42.0)
Y8.9150 Z-0.3500
(move x= 43.146725 GT max of 42.0)
Y8.9061 Z-0.3500
G17 G2 X43.0718 Y8.9167 Z-0.3500 R0.5625
X43.0011 Y8.9364 Z-0.3500 R0.5625
X42.9336 Y8.9651 Z-0.3500 R0.5625
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X42.6252 Y9.4336 Z-0.3500 R0.5625
X42.6255 Y9.5049 Z-0.3500 R0.5625
(move x= 42.665326 GT max of 42.0)
G1 X42.0000 Y10.0706 Z-0.3500
(move x= 42.526238 GT max of 42.0)
Y10.0822 Z-0.3500
(move x= 42.409858 GT max of 42.0)
Y10.0934 Z-0.3500
X35.3974 Y10.6910 Z-0.3500
X32.4178 Y10.9921 Z-0.3500
X32.3312 Y10.3898 Z-0.3500
G17 G2 X32.3175 Y10.3236 Z-0.3500 R0.5625
X32.2950 Y10.2577 Z-0.3500 R0.5625
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X32.0744 Y9.9956 Z-0.3500 R0.5625
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X31.7445 Y9.9101 Z-0.3500 R0.5625
G1 X29.1512 Y10.0587 Z-0.3500
G17 G3 X28.8754 Y10.0713 Z-0.3500 R12.0625
X28.5998 Y10.0775 Z-0.3500 R12.0625
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X28.0486 Y10.0709 Z-0.3500 R12.0625
X27.7732 Y10.0581 Z-0.3500 R12.0625
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X27.2237 Y10.0133 Z-0.3500 R12.0625
X26.9499 Y9.9814 Z-0.3500 R12.0625
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X26.1339 Y9.8479 Z-0.3500 R12.0625
X25.8639 Y9.7908 Z-0.3500 R12.0625
G1 X15.9439 Y7.5740 Z-0.3500
X13.9337 Y8.9815 Z-0.3500
G17 G2 X13.5390 Y8.6037 Z-0.3500 R1.5625
X12.9703 Y8.3825 Z-0.3500 R1.5625
X12.3603 Y8.3958 Z-0.3500 R1.5625
X11.8019 Y8.6416 Z-0.3500 R1.5625
X11.3800 Y9.0823 Z-0.3500 R1.5625
G0 Z0.1250
X9.2087 Y16.3619 Z0.1250
G1 Z-0.3500 F100
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X21.4797 Y20.1391 Z-0.3500
X22.1584 Y20.1751 Z-0.3500
X22.9809 Y20.2307 Z-0.3500
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X25.4545 Y20.3374 Z-0.3500
X25.9386 Y20.3553 Z-0.3500
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X28.8650 Y20.4415 Z-0.3500
X30.4158 Y20.3664 Z-0.3500
X31.7914 Y20.3553 Z-0.3500
X32.2755 Y20.3374 Z-0.3500
X34.1854 Y20.2618 Z-0.3500
X34.7491 Y20.2307 Z-0.3500
X35.5716 Y20.1751 Z-0.3500
X36.2503 Y20.1391 Z-0.3500
X36.9454 Y20.0927 Z-0.3500
X37.8621 Y20.0193 Z-0.3500
X38.4937 Y19.9684 Z-0.3500
X39.5372 Y19.8751 Z-0.3500
X40.1261 Y19.8193 Z-0.3500
X40.7324 Y19.7534 Z-0.3500
X41.4850 Y19.6695 Z-0.3500
(move x= 42.231720 GT max of 42.0)
X42.0000 Y19.5863 Z-0.3500
(move x= 42.837245 GT max of 42.0)
Y19.5117 Z-0.3500
(move x= 43.462614 GT max of 42.0)
Y19.4257 Z-0.3500
(move x= 44.135973 GT max of 42.0)
Y19.2935 Z-0.3500
(move x= 44.787514 GT max of 42.0)
Y19.1953 Z-0.3500
(move x= 45.419821 GT max of 42.0)
Y19.0720 Z-0.3500
(move x= 46.100260 GT max of 42.0)
Y18.9601 Z-0.3500
(move x= 46.494745 GT max of 42.0)
Y18.8547 Z-0.3500
(move x= 47.196616 GT max of 42.0)
Y18.7300 Z-0.3500
(move x= 47.575554 GT max of 42.0)
Y18.6298 Z-0.3500
(move x= 48.299006 GT max of 42.0)
Y18.4915 Z-0.3500
(move x= 49.207284 GT max of 42.0)
Y18.3049 Z-0.3500
(move x= 48.417682 GT max of 42.0)
Y17.8490 Z-0.3500
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(move x= 48.523783 GT max of 42.0)
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(move x= 45.704385 GT max of 42.0)
Y16.9034 Z-0.3500
(move x= 42.555695 GT max of 42.0)
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X11.3762 Y16.7881 Z-0.3500
X10.1122 Y16.5435 Z-0.3500
X9.2087 Y16.3619 Z-0.3500
G0 Z0.1250
G0 X0 Y0
M05
G0 Z0
M30
%


And I see a possible cause -- the material size is wrong (too thin and not big enough) -- how do I change this?

 

Okay, that helps -- the toolbar *kinda'* works in SU v8 for Mac, but I'll try it in SU v7 in WinXP.

It is much better in WinXP and v7. The Generate 3D GCode label is not shown, but the check box is there. But I am not going to make this any more complicated...

 

Okay, the good news is that I am not getting an error message.

The bad news is, the GCode file is just 1k and only has the header information -- no shapes show up in CNC USB.

I'm working from SU v7 in WinXP and the component of the imported DWG shapes is open.

 

Neil, can it be that you generated a code without the 'safe area' or that the 'safe area' was not on the parts with the phlatlies? That will generate an empty file.

Also, make sure you have the 'overhead gantry' box checked in the parameter window (the one E-T posted the picture of).

 

Thanks folks, I'll try again this evening -- and I missed the SketchUCam tutorials.

Should the safe area be the size of the foam, and then I'll place the pieces within the margins? I noticed that the origin is slightly affected by this.

If the imported DWG entities are in a SU component and the Safe Area is outside this, that sounds like it would be a possible cause, right?