Curved Crown molding

This is a project that been presented to me by a customer that came in with crown molding sample and a print out of is kitchen CAD design with the basic measurements. I took up the challenge and quote the project and I was in my way for something new!

Once the sample was scanned, I vectorized it and create the curve to extrude it on. The curved molding was modeled in nurbs based software MoI (January 2007 beta release) and toolpath in VETRIC's Cut 3D and V Carve PRO (profiling cutout). The molding has been machined on my ShopBot PRT Alpha.

Making the 3D model and program the toolpath wasn't much of the challenge as the 'How the #!*? I'm gonna machine that 3-3/4" thick part out of it's upper side?!'...



That what the machine look like once the rough toolpath was done! Guess what the surrounding floor was looking like...



Another view of the "chip load".



The customer was advised that I was going to "redraw" the molding profile from a scan so he prefer to have a straight section made for a perfect fit at the miter cut. The finish curved molding is 82" wide and about 12" tall from the front. I left both ends "as it" so the customer has final word on the miter cut. The profile itself is about 3-3/4" X 3-3/4" from it's normal view position.



The curved one took about 6 hours total (rough, finish and cut toolpath) to machine. I probably put 2 hours here and there for the sanding part as I wanted to provide this customer with a "almost-ready-to-install-pieces".
I end up cutting out the curved one with a band saw to remove most of the remaining and finish with a large flush trim bit and the belt sander. Even with a 2" cutting length of cut bit, I still had a 1-3/4" "anchor" to cut out...



Here you have proud Paco holding the finish part high, ready for delivery!

Stay tuned, more to come about "medium size" carving!