# The Spark Gap - Episode 5

- Show: [The Spark Gap](https://hardwarepodcasts.com/podcast/the-spark-gap)
- Published: 2014-07-14
- Length: 44m
- Page: https://hardwarepodcasts.com/podcast/the-spark-gap/2014-07-14-the-spark-gap-episode-5
- Listen: https://thesparkgap.net/the-spark-gap-episode-5

## Summary

Karl, a hobbyist engineer, details his custom-built 6040 CNC router, explaining his decision to replace the stock Chinese components with shielded cabling, aluminum motor mounts, and a Hitachi VFD to ensure reliability and 110V compatibility. He discusses the technical trade-offs between bipolar and unipolar stepper motors, highlighting why bipolar motors offer better torque for microstepping. Karl also describes solving a critical noise issue with limit switches by adding capacitors to the parallel port breakout board, and compares his DIY setup to commercial hobbyist machines like the Other Mill and Nomad.

## Chapters

- [0:00](https://hardwarepodcasts.com/podcast/the-spark-gap/2014-07-14-the-spark-gap-episode-5#t=0) Introduction: CNC Router Basics and History
- [5:41](https://hardwarepodcasts.com/podcast/the-spark-gap/2014-07-14-the-spark-gap-episode-5#t=341) Router vs. Mill Mechanics and Load Handling
- [8:08](https://hardwarepodcasts.com/podcast/the-spark-gap/2014-07-14-the-spark-gap-episode-5#t=488) Building a Custom 6040 CNC Router
- [18:11](https://hardwarepodcasts.com/podcast/the-spark-gap/2014-07-14-the-spark-gap-episode-5#t=1091) Bipolar vs. Unipolar Stepper Motors
- [23:39](https://hardwarepodcasts.com/podcast/the-spark-gap/2014-07-14-the-spark-gap-episode-5#t=1419) Solving Limit Switch Noise with Capacitors
- [29:25](https://hardwarepodcasts.com/podcast/the-spark-gap/2014-07-14-the-spark-gap-episode-5#t=1765) Commercial Hobbyist Routers: Other Mill and Nomad
- [36:15](https://hardwarepodcasts.com/podcast/the-spark-gap/2014-07-14-the-spark-gap-episode-5#t=2175) CAD/CAM Software Challenges and Spindle Quality

## Topics

- [Mechanical engineering](https://hardwarepodcasts.com/topic/mechanical-engineering)
- [Embedded firmware](https://hardwarepodcasts.com/topic/embedded-firmware)
- [Fabrication & craft](https://hardwarepodcasts.com/topic/fabrication-and-craft)
- [EDA & CAD tools](https://hardwarepodcasts.com/topic/eda-and-cad-tools)
- [Chips, FPGAs & semiconductors](https://hardwarepodcasts.com/topic/chips-and-fpgas)

## Most relevant to

makers and hobbyists

## Mentioned

- Bridgeport (other)
- Instructables (other)
- ShapeOko (product)
- Open Beam (company)
- Allegro A3977 (chip)
- Nema 23 (other)
- 8020 (other)
- Other Mill (product)
- Nomad (product)
- TinyG (other)
- MeshCAM (other)
- OpenSCAD (other)
- Blender (other)
- HacksCNC (other)
- MakerCam (other)
- CamBam (other)

## Related episodes from other shows

- [Ep. 33 - Guest: Bar Smith of Maslow CNC](https://hardwarepodcasts.com/podcast/open-hardware-manufacturing-podcast/2024-11-21-ep-33-guest-bar-smith-of-maslow-cnc) (Open Hardware Manufacturing Podcast)
- [Ep 154: A Good Enough CNC, Stepper Motors Unrolled, Smart Two-Wire LEDs, a Volcano Heard Around the World](https://hardwarepodcasts.com/podcast/hackaday-podcast/2022-02-04-ep-154-a-good-enough-cnc-stepper-motors-unrolled-smart-two-wire-leds-a-volcano-h) (Hackaday Podcast)
- [STL290: Lightning round with Vic and Ben](https://hardwarepodcasts.com/podcast/shop-talk-live/2023-05-05-stl290-lightning-round-with-vic-and-ben) (Shop Talk Live)
- [STL231: Fancy router tables vs. plywood with a hole in it](https://hardwarepodcasts.com/podcast/shop-talk-live/2020-12-18-stl231-fancy-router-tables-vs-plywood-with-a-hole-in-it) (Shop Talk Live)
- [160: Chowdered up the Spoilboard](https://hardwarepodcasts.com/podcast/embedded-fm/2016-07-12-160-chowdered-up-the-spoilboard) (Embedded.fm)

## Citing this page

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