Can you Machine an Aluminum Can?

Yes you can!

(Project Files and build details are below)

Japanese Paper Craft was the initial inspiration for this project, and several years ago I adapted a Paper Robot design from paperrobots1999.com to fit onto an Aluminum can, this was before the Nomad and I had to print the design on Sticker Paper and then cut them with scissors. The Down side was that I could never cut them accurately or repeatably to confirm my design, so it got put in a project box and forgotten for 5 years.

Now, with the Nomad, whose middle name is Accuracy and Repeatability, I can make Shiny Metal Robots all day long!

Heres the Final Robots and Parts:



Coke Vs. Pepsi Vs. Nomad

Carbide Create Design File

To help fold the small parts I first ran a toolpath of all the holes, which included the Axle holes, but also holes at all the fold points.

Carbide Create Cut Preview:



All the parts to build one 3" tall Articulated Robot, including a spare Helmet and some extra Hips and Shoulders.The aluminum can canvas measures 8" x 3.6" x .005"

Work Holding the Aluminum Can:



For Metal, I usually go with the Blue Wax, but even after Sanding the thin plastic layer and wiping the can with acetone, the wax would release the aluminum sheet during the cut. ( I think the thin material wont hold the necessary heat to bond with the wax properly)Hot Glue does work to Hold the Aluminum, but introduces a Challenge of an un-even work surface.The Solution is easy though, I set my DOC to .045" which put the tool into and through the .005" aluminum across the bed- regardless of the .030" variation found across the work.I zeroed of the Acrylic wasteboard, and then jogged up .046" and zeroed the z again.FYI: Rubbing alcohol will release Hot Glue, but it cracks acrylic. If you look closely at the video you can see the cracks at the bolt holes.

The Exploded Parts/ Construction sketch



Under 20 cents in Raw materials!



Fold, Pinch, Repeat. I placed an extra tab wherever possible, so you just fold the parts into square tubes, and pinch over the final small tabs. (Kinda like a Tonka truck)Resistor wire, some PCB donuts, solder and a spring.Boom, you got a Robot.

The Stop Motion Secret:



The Key to getting the Robots to stand up is Friction created by internal tension. I was able to create this by capturing the hip joints by soldering PCB Donuts onto either side of a resistor and then winding a small spring (a retractable pen spring will work) into the body.I could never have planned for that to work, just one of the results of fiddling around until it does.

Heres a link to the Files:

Dropbox SodaPOProbot Shared with Dropbox

If you have any questions let me know!



If you have too much fun with these, also let me know.