4-Axis WEDM is a Reality!
Intro
Hi again, long time no see! Cooper here.
We've had a crazy last few months here at the shop, but things have stabilized and I'm ready to share some great news with everyone. The biggest one is the success of our 4-axis tests with the Betta Wire. This is a huge milestone and it means we can start converting the Betta Wire Pre-Order deposits and move towards shipping!
Betta Wire 4-Axis Success
Just today I made our first successful 4-axis cut on the Betta Wire, and I couldn't be happier. It's taken a lot of work over the past few months to nail down toolhead fine-tuning and firmware adjustments, especially with our move to the new Mesa 7C80 mainboard, but it's all been worth it.
One of the most interesting realizations I've had recently is that there really is no roadmap. We're doing something here that has never been done on this scale and we need to be especially creative. When we started, we didn't really even know if it was possible, but we've kept at it, and today has proved that it is!
Above, you can see our first tapered cut. This was a basic 5mm offset between the XY and UV axes of the Betta Wire, but I believe it shows a great deal of promise. Especially in a more difficult to machine test piece like this 19mm thick aluminum. If you want to see the full cut, check out our video on the Rack Robotics X page!
Closed loop controls work based on Powercore feedback, wire control works via our belt system, flushing of the cut works via a new resin plenum, and energizing the wire is entirely passive. This means operation of the machine will be extremely easy, even if a wire breaks and rethreading is required.
There is still more work to do on firmware and quality of life stuff, but this sort of amazing output is exactly why I've been pushing so hard recently.
The Journey So Far
I'm incredibly happy with how far the Betta Wire has come. We've overcome innumerable technical challenges and completing these test cuts feels like a real triumph. Still, it's a little bittersweet.
You have probably noticed a lack of updates and the slow rollout of the Betta. For everyone who isn't in the Discord, I feel the need to be fully transparent. Back at the end of the past November, John (my co-founder) and Nick left the team. Since then, I've been working on the project solo.
It's been one of the most challenging periods I've faced, mentally, physically, and emotionally. Despite that, I've kept the business alive, made insane progress, and today's success proves that the Betta Wire is ready. I'm feeling energized and more ready than ever to ensure that you get these machines and that affordable wire EDM proliferates throughout the world.
Betta Wire Finalization
New media will be uploaded to the site in the next few days(mostly updated Betta Wire pictures), as well as updated CAD files to our Printables Betta Wire page. We've scrapped almost all of the scope creep from the design, while retaining the most important discoveries and improvements found along the way.
I've done my best to pair down the Betta Wire to the very most important technical aspects, while removing extraneous and unnecessary "improvements". We've reverted back to a mainly 3D printed frame while significantly simplifying assembly. The rigidity of the design is more than enough for the intended purpose, as we've seen today.
We're retaining a few laser cut and machined components, however. The energizer is probably one of the best improvements. It uses a machined aluminum block and two aluminum plates to completely passively join the wire into the circuit. This is probably my favorite innovation because it removes so much complexity from the system and makes it far easier to build and use.
With a new video dropping hopefully next week, I'm certain you're all going to like what you see.
Next Steps
Now that machine function has been verified (not only on the Betta but on other machines extensively) and we're moving imminently towards Betta Wire fulfillment, I would encourage those of you who have made the $100 pre-order deposit to complete your order. Simply purchase the Betta Wire that is on our webstore, add a note to your order with your deposit number, and we'll give you 3x your deposit value rebated off the order as a big thank you for your patience.
We're in an incredible position as a community. 4-axis desktop wire EDM has never been a reality before, and now it is. We can get it into schools, homes, and small businesses all across the world. We've already been serving Wire Tool Kits to communities across the globe.
We're well on our way to another RepRap moment, and I'm so glad you've stuck around for the ride. I wouldn't still be doing this if not for the support of the community. I hope to continue serving you all for a long time.
-Cooper