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Initialization
1) Turn on the control module.
2) Open IsoPro.
Design Import
3) File->ImportàDrill Files. <Fig. 1>
4) File->ImportàGerber Files. <Fig. 2>
Figure 1: Import Drill Files. Figure 2: Import Gerber Files – Set Precision.
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Isolation
10) ToolsàIsolate (Top and Bottom layer). <Fig. 7,8>
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Figure 12: Verify the Bottom and Board Outline layers are mirrored
14) Verify bottom isolation layer and board isolation layer are “mirrored”.
15) Click ‘OK’.
16) Save an .iso file.
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Manufacturing Setup
17) MillàInitialize.
18) MillàMaterial Change.
19) Mount Board Material.
• Drill first mounting hole. <Fig. 13>
• Insert first dowel pin to align the board and the backing material. <Fig. 14>
• Drill second mounting hole while lining up the board. <Fig. 15>
• Insert the first dowel pin into the “Primary Pinning Hole” on the milling
table. <Fig. 16>
Figure 13: Drill the first mounting hole. Figure 14: Align the board and backing material
with a dowel pin.
Figure 15: Drill the second mounting hole. Figure 16: Insert the first dowel pin into the
“Primary Pinning Hole”.
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• Place board and backing material on the dowel pin in the “Primary Pinning
Hole”
• Insert second dowel pin through board and backing material into groove
for alignment. <Fig. 17>
• Tape down the board and the buffer material. <Fig. 18>
Figure 17: Place buffer material and board on Figure 18: Tape down board and buffer
dowel pins. material.
Figure 19: All layers selected to align to board material. Figure 20: Offset toolbar button
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• EditàDeselectàAll Data.
• Verify Design Location.
i. Right click on opposite corners of the Board Outline.
ii. MachineàJump to Cursor.
iii. Verify that the machine moves from corner to corner where you
want board to be machined. <Fig. 22,23>
Figure 22: Top-Right corner verification. Figure 23: Bottom-Left corner verification.
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Drilling
21) Mill->Tool Change.
• Insert the proper drill bit. <Fig. 24>
• Set drill bit depth using spare board material as a gauge. <Fig. 25,26>
Figure 24: Insert the proper drill bit. Figure 25: Use Spare board material to set
drill bit depth.
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• Push down on the mill head assembly and verify that pressure foot
bumper will contact the board; if not, loosen solenoid knob until it would.
• Check visually that top stop is high enough to allow drill bit to clear board.
• Press ‘OK’ (Tool will return to the previous location).
• Adjust top stop until drill bit is approximately 1/16 inch above the board.
22) Right click the drill layer in the layer list.
23) Run layer. <Fig. 27>
• Head will move to tool change.
• Verify the proper drill bit is inserted.
• Hit ‘OK’.
24) Repeat for each drill bit (only drill bit depth may need adjustment, other settings
will remain the same).
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Milling
25) Right click the “TOP” isolated layer.
26) Run layer.
• Set Tool ParametersàInches/min to 10 (important). <Fig. 28>
• Insert proper end mill.
• Adjust Knurl Nut so that the pressure foot bumper is below the end mill (so
that no cutting will be possible at first).
• Adjust top stop so that pressure foot bumper will clear the board.
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Flip Board
27) When milling the Top layer is complete, MillàMaterial Change.
28) Untape the board.
29) Flip the board (not the buffer material) maintaining the dowel pins in their
respective holes.
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Contour Routing
32) Mill->Tool Change.
33) Insert contour router bit.
34) Set mill adjustments using the same process from drilling (Step 21).
35) Right click Board Outline layeràRun Layer.
36) Select Contour Router in Tool Parameters
37) Change Tool ParametersàInches/min to 3 (important). <Fig. 30>
38) Click ‘OK’.
Cleanup
39) Click MillàTool Change and remove your tool.
40) Click MillàMaterial Change.
41) Untape and remove your board and the buffer material.
42) Dispose of all tape.
43) Return the dowel pins, buffer material, and the Allen wrench to the drawer.
44) Dispose of any leftover board material.
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Reference Figures
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