Now we get to the meat of the project. Creating the G-Code. Again, I am going to use Halftoner v1.5 for this example.
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Metric Metric Metric!!!
I cannot tell you what a headache it was to work in inches when everything (including the X-Carve itself) is laid out in millimeters. That aside, there seems to be an error in Halftoner that will not convert from inches to millimeters when writing the G-Code (or maybe the sender needs to know that the data is inches). Save yourself some frustration and heed this advice!
Generator
This tab allows you to define the specifications of the halftone itself. Most of it is self explanatory. My experience thus far is to make a halftone that is at least 400mm in one direction. Anything smaller and you have to make too small of holes or too few to get it to fit and the result doesn't have enough detail. I think spacing needs to be at least or slightly smaller than the max size and the measurement is from origin to origin of each hole. This means that if do not change the spacing but change the max size, the number of holes will not change, they will just get grouped closer together as you increase the size. You can experiment with the other setting and see what will happen in the preview. The screen shot shows the settings I used for this example.
Toolpath
Since I am using a Dewalt 611 router that is not controllable in speed by the software, the only settings that mean anything are Safe Z, Feed and Tool Angle.
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- Safe Z – This is the minimum height your bit will be raised above the surface of your material prior to movement to the next location. Essentially the rule is, the higher it has to go before moving, the longer it will take to finish your project. Even a slight adjustment to this will have substantial effects to this time. So long as the bit clears the material anything above that minimal clearance is a waste of time.
- Feed – This controls how quickly your CNC machine actually moves up and down. I don't have any experience with changing this setting so I will update this part as I get more time to experiment.
- Safe Z – This is the minimum height your bit will be raised above the surface of your material prior to movement to the next location. Essentially the rule is, the higher it has to go before moving, the longer it will take to finish your project. Even a slight adjustment to this will have substantial effects to this time. So long as the bit clears the material anything above that minimal clearance is a waste of time.
- Feed – This controls how quickly your CNC machine actually moves up and down. I don't have any experience with changing this setting so I will update this part as I get more time to experiment.
Halftone
- Tool angle – This is the slap your head cuz you're a moron setting. I don't know how long I had been trying to get good results using a 90 degree bit and setting this to 45 degrees. I mean it's 45 degrees. Right? It looks like it. No it doesn't even look like it you idiot! lol. Ok, after setting this correctly things started pulling together. A 90 degree bit will cut shallower holes than a 60 degree bit. Makes sense, right? But be aware that, as in my case, some material is quite thin. So I used a 90. If you use 3/4 ply or some other thick material, a 60 degree bit is more forgiving for a less smooth surface.
Online Halftone Generator
Side note
Halftone Background
The author of this software, Jason Dorie, actually responded a few times to emails when I was trying to find all the right settings. For this reason alone, I highly recommend the software and to donate to his cause (PayPal link in his web page). Thanks Jason!
