DIY CNC Waterjet Ceramic Tile Cutting Machine Version 1

My intention for this, my first Instructable, is to document a tool project I constructed over 18 years ago. I call it my version 1, because I have done a more recent version 2, which I plan to describe in my next Instructable. Version 1, none the less, remains a unique construction.

The version 1 project was to use a surplus old computer and scanner peripherals to construct a CNC waterjet machine that could make, mosaic like, precision fit ceramic tile compositions.

I did this with limited experience with clay ceramic processing, but with a fair amount of experience with machine design and computer programming.

Most all parts used would be hard to find today, but substitute parts are easy to imagine if one wanted to make something similar today.

1)  Build a 2-axis CNC table, from 2 old computer scanners(new cost > $1000 new, < $7 at Goodwill thrift store)

2)  Make CNC controller from an old IBM PC(1980’s vintage – IBMDOS)(>$1500 new - $1.69 at Goodwill thrift store)

3)  System integration:

a)  Made a custom tile holder from metal casting(recycled aluminum), strung with piano wire for tile support.

b)  Wrote a custom VB for applications app in Intellicad CAD program for converting 2D CAD drawing components into individual G-code files.

c)  Constructed 3-axis stepper motor driver from mail order kit.

d)  Converted an inexpensive sidewalk pressure washer to mount to the CNC table.

e)  Built a water circulation/ filtration/ recycling tank system.

f)   Made plaster molds for production of standardized 6 by 6 by ¼ inch greenware clay tiles( using the slip casting method).

The primary goal for me was to be able to make ceramic tiles that fit together precisely, in Echer-like tiling patterns. And since industrial waterjet machines were extremely expensive, I thought, what could I do with a $99 sidewalk pressure washer? This corresponded with a ceramics class I recently took and thought that maybe the low pressure(washer) could cut “greenware” ceramics(clay that is dried but not fired). So that ended up working like cutting thru butter.

Then, another aspect I learned from the ceramics class was that clay items made with a replicating process called slip casting would maintain very precisely the same shape in 3D after they are fired, all be it slightly smaller. Traditional rolled out sheets of clay for tile making can shrink at different rates in the 3D directions. So I made the plaster molds to do slip castings of my raw material tiles, which then fit into the CNC to be cut out into custom shapes.

Those greenware tiles are placed into my CNC machine, the pressure washer turned on, CNC controller moves the pressure washer to cut the pattern, with water being collected/filtered and returned to the pressure washer.

I then dry the cut tiles and fire them(bisk/glaze)

Then they can be mounted wherever, just like standard ceramic tiles.

I used two different brands of scanners, one had two narrowly spaced rows of round rails, where the other had a wider spaced set of rails. The scanners were stripped of all casing and electronic parts leaving only the rails, stepper motors, and the basic travelling mirror holding carriages.

The overall supporting frames were cut where necessary to provide a rectangular thru hole space and mounted 90 degrees apart to provide X-axis/ Y-axis motions.

I made a mount for the pressure washer wand by metal casting a bracket, between the narrow rails scanner(which is mounted on top of the other scanner)

On the wider rails scanner I mounted a custom made rectangular frame strung with piano wire. (instructions for casting this with recycled aluminum will have to wait for a separate instructable)

I also added a third stepper to the handle of the pressure washer wand to be able to let gcode operate the on/off function of the pressure washer.

Then I mounted the table over an old washing machine tub to collect the water after it cuts the tiles.

I Used an old vintage IBM PC x-386 running DOS.

CNC controller program available was DeskNC for DOS.

No change to computer required, just output thru a parallel port w/cable.

Kit ordered online direct(sorry no Amazon at the time)

Parallel port input to  3 axis 4-wire to drive stepper motors.

Intellicad drafting program on windows NT computer.

Program included Visual Basic for Application extension, with which I wrote a small program to convert any drawing selection into a gcode path and save to file.

DeskNC for DOS – Sends gcode files via a parallel port to stepper motor driver( assembled from kit).

I made plaster molds to cast ceramic clay slip into.

Once cast and removed from molds the greenware tile were left to dry to what is called bone dry. (Note – at this stage of ceramics the tiles will dissolve in water)

1)Greenware tile is placed into the CNC machine.

2)Gcode file for any particular tile design is loaded into DeskNC program.

3)Water turned on and pressure washer machine turned on.

4)Gcode file sent to CNC machine.

5)Tile cut.

6)Turn off machine.

7)Bisue and glaze fire the cut greenware tiles.

8)Assemble as required for finished tile installation.

This instructable is probably a vanity project for me, in that being 74 yo, I have done a lot of my maker projects prior to online social networks, so this is sort of for historical record(but could be replicated if interested). And sorry for my limited ability to recall more step by step photos of my building process 18 years ago.