Design and fabrication of a 5-Axis CNC milling machine

Abstract

This thesis details the design, mechatronic integration, and software configuration of a low-cost 5-axis CNC milling machine prototype featuring a bi-rotary head. The work covers the mechanical assembly of the structural frame, the optimization of a strategically zoned electrical cabinet governed by an ST-V3 motion controller, and the digital configuration within Mach3. To enable simultaneous 5-axis trajectory generation, a custom SolidCAM post-processor was developed by modifying the machine’s VMID and GPP files. Finally, a Business Model Canvas (BMC) framework is applied to evaluate the commercial viability and industrial potential of the prototype.