CNC ROUTER

1. INTRODUCTION :
1.1 AIM AND OBJECTIVE
Aims of this project work are,
• To develop a cost-effective CNC router capable of performing precise machining tasks
with a bed size of 3018.
• To utilize commonly available materials and components, ensuring accessibility and
affordability without compromising performance.
• To explore the potential applications of the CNC router, including PCB milling,
woodworking, and prototyping.
Objectives of this work are,

• Designing a CNC router that integrates a GRBL controller system for precise motion
control and ease of use.
• Utilizing NEMA 17 motors for axis movement and a 775 motor for spindle rotation to
strike a balance between power and precision.
• Employing A4988 drivers for stepper motor control within the frame to ensure smooth
and reliable operation during intricate machining tasks.
• Achieving high precision and repeatability in machining tasks while maintaining
reasonable costs, thereby making CNC technology more accessible to a broader
audience.
•
1.2 MOTIVATION

The motivation behind this project is twofold. Firstly, there is a growing demand for affordable
CNC solutions that can cater to hobbyists, educational institutions, and small businesses.
Commercial CNC routers, while offering advanced features, are often cost-prohibitive, limiting
their accessibility. By developing an affordable CNC router, this project aims to democratize
access to CNC technology and empower a wider demographic to explore its capabilities.

Secondly, the project is driven by a passion for innovation and hands-on learning. By
embarking on the journey of designing and building a CNC router from scratch, participants
gain practical insights into mechanical design, electronics integration, and motion control
systems. This hands-on experience fosters a deeper understanding of CNC technology and
equips participants with skills highly relevant in today's technological landscape.

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1.3 LITERATURE AND SURVEY:

A comprehensive review of existing literature and projects in the field of CNC routers reveals
a rich tapestry of innovation and creativity. Various online forums, blogs, and tutorials serve
as repositories of knowledge, offering valuable insights into different design approaches,
component selection criteria, and performance optimization techniques. Projects such as the
Shapeoko, OpenBuilds, and the MPCNC have emerged as prominent examples within the DIY
CNC community, showcasing the ingenuity and resourcefulness of enthusiasts worldwide.

Furthermore, the potential application of CNC routers in PCB milling has gained significant
attention due to its ability to produce precise and complex circuit board designs. By leveraging
the capabilities of the CNC router developed in this project, enthusiasts and small-scale
manufacturers can fabricate PCBs with high precision and repeatability, opening up new
possibilities for electronics prototyping and production.

This expanded introduction provides a comprehensive overview of the project's aims,

objectives, motivations, and the existing literature and survey within the field of CNC routers,
including its application in PCB milling. It sets the stage for the subsequent sections of the
report, providing a clear context for understanding the significance and scope of the project.

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2. SYSTEM DESIGN
2.1 SYSTEM BLOCK DIAGRAM

Fig 1.System block diagram

Operation:

1. PC (Computer):

• Design File Creation:

• Use CAD (Computer-Aided Design) or CAM (Computer-Aided Manufacturing)

software to create the design file.

• Design intricate shapes, patterns, or prototypes according to project requirements.

• G-code Generation:

• Convert the design file into G-code, a language understood by CNC machines, using
appropriate software.

• Specify toolpaths, cutting speeds, and other machining parameters in the G-code file.

2. GRBL CNC Controller Control Board:

• G-code Interpretation:

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• Receive the G-code file from the PC via a USB connection.

• Parse the G-code commands to extract motion instructions and other parameters.

• Signal Generation:

• Generate precise signals for the NEMA 17 stepper motors based on the parsed G-
code commands.

• Ensure synchronization and coordination of movements across multiple axes.

3. A4988 Stepper Drivers:

• Signal Amplification:

• Amplify the control signals received from the GRBL CNC Controller Control Board
to drive the NEMA 17 stepper motors.

• Ensure accurate translation of digital signals into precise motor movements.

• Microstepping Control:

• Implement microstepping technology to achieve finer resolution and smoother

motion for the NEMA 17 stepper motors.

• Adjust microstepping settings based on specific machining requirements and motor

characteristics.

4. NEMA 17 Stepper Motors:

• Motion Execution:

• Receive step and direction signals from the A4988 drivers to move along the X, Y,
and Z axes.

• Execute linear movements with high precision and repeatability.

• Torque Generation:

• Generate sufficient torque to overcome mechanical resistance and drive the CNC
machine components.

• Maintain positional accuracy and stability during machining operations.

5. Limit Switches:

• Physical Boundary Detection:

• Detect the physical limits of the CNC machine's travel along each axis.

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• Trigger a stop signal to halt machine movement when a limit is reached, preventing
over-travel and potential damage.

• Homing Functionality:

• Provide reference points for homing the CNC machine at the start of each machining
operation.

• Ensure consistent and repeatable positioning accuracy.

6. SMPS (Switched-Mode Power Supply):

• Stable Power Delivery:

• Convert AC input voltage to DC output voltage with high efficiency and minimal
ripple.

• Provide stable and reliable power to all components of the CNC system.

• Overload Protection:

• Implement safeguards against overcurrent, overvoltage, and short circuits to protect

sensitive electronic components.

• Ensure safe operation under varying load conditions.

7. Speed Controller and Spindle Motor (775):

• Speed Regulation:

• Adjust the rotational speed of the spindle motor to accommodate different machining
requirements.

• Control spindle speed dynamically based on material type, cutting tool geometry, and
desired surface finish.

• Tool Compatibility:

• Support a variety of cutting tools, including end mills, router bits, and drills, with
different shank sizes and cutting diameters.

• Ensure compatibility with standard tool holders and collets for secure tool retention
during machining.

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2.2 METHODOLOGY:

The methodology section outlines the systematic approach used to design, develop, and
implement the CNC router project. It encompasses various stages from conceptualization to
the final assembly and testing. The following steps were undertaken:

1. Project Planning and Requirement Analysis:

• Define project objectives, scope, and constraints.

• Identify specific requirements such as bed size, motor types, controller, and spindle
specifications.

• Determine project timeline and allocate resources accordingly.

2. Research and Component Selection:

• Conduct comprehensive research on DIY CNC router designs, components, and best
practices.

• Evaluate various options for stepper motors, drivers, controllers, and other essential
parts based on performance, compatibility, and cost-effectiveness.

• Select suitable components such as NEMA 17 stepper motors, A4988 stepper drivers,
GRBL CNC controller, and 775 spindle motor.

3. Design and Prototyping:

• Develop a detailed design plan encompassing mechanical, electrical, and software

aspects.

• Create CAD (Computer-Aided Design) models of the CNC router structure using
software like Fusion 360 or SolidWorks.

• Prototype critical components and subsystems to validate functionality and

performance.

4. Assembly and Integration:

• Procure necessary materials and components based on the finalized design.

• Assemble the mechanical frame using aluminum extrusions, smooth rods, and T8
rods, ensuring precise alignment and structural stability.

• Integrate electronic components such as stepper motors, drivers, limit switches, and
power supply into the CNC router framework.

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• Connect wiring harnesses and ensure proper cable management to minimize

interference and ensure safety.

5. Software Configuration and Calibration:

• Install and configure GRBL firmware on the CNC controller board.

• Establish communication between the PC and CNC controller using appropriate
software (e.g., Universal Gcode Sender).
• Calibrate stepper motor settings, including steps per millimeter, acceleration, and
maximum feed rates, to optimize performance and accuracy.
6. Testing and Validation:

• Conduct comprehensive testing of individual components and subsystems to identify

any issues or deficiencies.
• Perform initial dry runs to verify motion control, homing, and limit switch
functionality.
• Conduct test cuts and milling operations on various materials to evaluate accuracy,
surface finish, and repeatability.
7. Refinement and Optimization:

• Analyze test results and identify areas for improvement.

• Fine-tune machine parameters, such as acceleration, jerk, and spindle speed, to
enhance performance and efficiency.
• Address any mechanical or electrical issues through iterative refinement and
troubleshooting.
8. Documentation and Reporting:

• Document the entire design and development process, including design

specifications, assembly instructions, and test results.
• Prepare a comprehensive report documenting the methodology, challenges
encountered, solutions implemented, and lessons learned during the project.
By following this methodology, the CNC router project was successfully executed, resulting
in the development of a functional and reliable DIY CNC router capable of fulfilling its
intended machining tasks.

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2.3 HARDWARE DESIGN TECHNIQUES:

1. Frame

2. Spindle Assembly

3. Stepper Motors (NEMA 17)

4. Stepper Motor Drivers (A4988)

5. CNC Controller Board (GRBL-Compatible)

6. Spindle Motor (775) With ER11 chuck

7. Heat Dissipation and Cooling

8. Wiring Harnesses

9. Limit Switches

10. Power Supply

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1. Frame:

• Description: The frame provides the structural foundation for the CNC router,
supporting all other components and ensuring stability during operation. It is
constructed using modular aluminium extrusions (20x20 profile), corner brackets,
fasteners (screws, nuts, bolts), smooth rods, and T8 rods, along with levelling feet.

• Detail Information: In addition to aluminium extrusions, smooth rods and T8 rods

are incorporated into the frame design to guide and support the movement of CNC
router components. Smooth rods are typically used for linear motion systems such as
the gantry or linear guides, providing smooth and precise movement along specific
axes. T8 rods are often utilized for driving mechanisms such as lead screws, enabling
accurate positioning and movement control. These rods are strategically positioned
and secured within the frame structure to ensure proper alignment and functionality
of the CNC router.

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2. Spindle Assembly

• Description: The spindle assembly holds and drives the cutting tool (end mill, router
bit) during machining operations.

• Parts Used: Spindle motor (775), ER11 collet chuck, spindle mount, bearings,
pulleys, belts, and fasteners.

• Detail Information: The spindle motor provides rotational motion to the cutting tool.
The ER11 collet chuck securely grips the tool, allowing for easy and precise tool
changes. Bearings support the spindle shaft, reducing friction and ensuring smooth
operation. Pulleys and belts transmit power from the motor to the spindle shaft,
allowing for variable speed control and torque transmission.

3. Stepper Motors (NEMA 17):

• Description: Stepper motors provide precise control of movement along the X, Y,

and Z axes of the CNC router.

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• Parts Used: NEMA 17 stepper motors (e.g., "NEMA 17 Stepper Motor Bipolar 2A
59Ncm (84oz.in) 48mm Body 4-lead W/ 1m Cable and Connector for 3D
Printer/CNC XYZ Axis").

• Detail Information: NEMA 17 stepper motors are commonly used for their compact
size, high torque, and compatibility with CNC applications. They feature a 1.8-degree
step angle, allowing for precise positioning and control.

4. Stepper Motor Drivers (A4988):

• Description: Stepper motor drivers convert digital signals from the CNC controller
into precise movements of the stepper motors.

• Parts Used: A4988 stepper motor drivers.

• Detail Information: The A4988 stepper motor driver is a widely used driver module
capable of micro stepping and providing sufficient current for NEMA 17 stepper
motors. It features adjustable current limiting, thermal shutdown, and overcurrent
protection.

5. CNC Controller Board (GRBL-Compatible):

• Description: The CNC controller board interprets G-code commands from the PC
and controls the movement of stepper motors and other peripherals.

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• Parts Used: GRBL-compatible CNC controller board (e.g., "GRBL CNC Controller
Control Board for XYZ axis").

• Detail Information: The GRBL-compatible controller board features USB

connectivity for communication with the PC, along with dedicated stepper motor
drivers and limit switch inputs. It runs the GRBL firmware, which is specifically
designed for CNC applications and provides real-time control and feedback.

6. Spindle Motor (775) With ER11 chuck:

• Description: The spindle motor provides rotational motion to the cutting tool for
milling and cutting operations.

• Parts Used: 775 DC motor with ER11 chuck (e.g., "775 DC Motor 12V-36V 3500-
9000RPM Motor Large Torque High Power Motor").

• Detail Information: The 775 DC motor is commonly used in DIY CNC applications
for its high torque and variable speed capabilities. It operates on a wide voltage range
and can achieve speeds suitable for various machining tasks.

7. Heat Dissipation and Cooling:

• Description: Heat dissipation and cooling measures are implemented to prevent

overheating of electronic components and ensure reliable operation.

• Parts Used: Heat sinks, cooling fans, and thermal paste.

• Detail Information: Heat sinks are attached to components such as stepper motor
drivers and spindle motor controllers to dissipate heat. Cooling fans are used to
improve airflow and enhance heat dissipation. Thermal paste is applied between
components and heat sinks to improve thermal conductivity and maximize heat
transfer.

8. Wiring Harnesses:

• Description: Wiring harnesses organize and route electrical connections between

components, ensuring proper connectivity and minimizing clutter.

• Parts Used: Cables, connectors, cable sleeves, and cable ties.

• Detail Information: Wiring harnesses consist of cables of appropriate gauge and

connectors compatible with the respective components. Cable sleeves and ties are
used to bundle and secure cables, reducing the risk of tangling and damage.

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9. Limit Switches:

• Description: Limit switches provide physical boundary detection to prevent over-

travel and ensure safe operation of the CNC router.

• Parts Used: Microswitches, mounting brackets, and wiring.

• Detail Information: Microswitches are mounted at the ends of each axis to detect
when the machine reaches its physical limits. When triggered, they send signals to
the CNC controller to halt movement.

10. Power Supply:

• Description: The power supply converts AC input voltage to DC output voltage to

power electronic components of the CNC router.

• Parts Used: Switched-mode power supply (SMPS) with 24V output voltage, 5A
current rating, and 120W power output capacity, terminal blocks, and wiring.

• Detail Information: The SMPS provides stable 24V DC voltage to the CNC
controller, stepper motor drivers, spindle motor, and other components. With a
current rating of 5A and a power output capacity of 120W, it ensures sufficient
power delivery for the operation of all CNC router components. Terminal blocks
are used for connecting input and output power cables, ensuring secure and reliable
connections.

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3. SYSTEM IMPLEMENTATION
3.1 CIRCUIT DIAGRAM

Fig . Circuit Diagram

In above circuit diagam shows that the the circuit diagram for the CNC router setup depicts the
electrical connections between various components. It illustrates the flow of power from the input
source to each component, including the CNC controller board, stepper motor drivers, spindle
motor controller, limit switches, and cooling fans. Each component is interconnected according to
its function and requirements, ensuring proper operation and control of the CNC router system.

3.2 ALGORITHM:
Step 1: Initialization
• Initialize variables and parameters required for CNC operation, such as feed rate,
spindle speed, and cutting depth.
Step 2: File Parsing
• Read the G-code file generated by the CAM software.

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• Parse the G-code commands to extract motion commands (e.g., G0, G1), spindle
control commands (e.g., M3, M5), and other relevant instructions.
Step 3: Motion Planning
• Interpret motion commands to determine the desired toolpath for the CNC machine.
• Convert toolpath coordinates to stepper motor step pulses for each axis (X, Y, Z).
• Implement acceleration and deceleration profiles to ensure smooth and precise
motion.
Step 4: Toolpath Execution
• Send the stepper motor step pulses to the CNC controller board.
• Control the movement of the stepper motors according to the planned toolpath.
• Monitor the position feedback from limit switches to prevent over-travel and ensure
safe operation.
Step 5: Spindle Control
• Interpret spindle control commands to adjust the spindle speed (e.g., M3 for spindle
ON, M5 for spindle OFF).
• Set the desired spindle speed based on the machining operation and material being
processed.
Step 6: Safety Checks
• Implement safety checks throughout the machining process to detect any anomalies or
errors.
• Monitor system parameters such as motor temperatures, power supply voltage, and
tool wear.
• Halt operation and trigger an alert if any safety thresholds are exceeded.
Step 7: End of Program
• Execute post-processing tasks such as tool retraction and machine shutdown.
• Generate a report detailing the machining process, including any errors or warnings
encountered.
• Prepare the CNC router for the next machining operation or shutdown.

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3.3 FLOWCHART:

START

Check if G-code file exists Step 1:

Initialization

Parse G-code commands Step 2: File Parsing

1. Interpret motion commands

Step 3: Motion
2. Convert coordinates to motor Pulses
3. Implement acceleration profiles Planning

1. Send pulses to CNC controller Step 4: Toolpath

2. Monitor limit switches Execution

1. Interpret spindle commands Step 5: Spindle

2. Adjust spindle speed Control

1. Monitor system parameters Step 6: Safety

2. Check for errors or anomalies Checks

1. Execute post-processing tasks Step 7: End of

2. Generate report Program

STOP

Fig 11. Flow chart of system

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4. RESULT AND CONCLUSION

4.1 RESULT:

The experimentation revolves around assessing key parameters essential for CNC router
functionality, such as spindle motor performance, material compatibility, and tooling
efficiency. Each parameter is meticulously examined to gauge its impact on machining
precision, speed, and overall output quality

Fig. Actual CNC Router Setup

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Some of the samples made by CNC Router

Fig .PCB Milling

Fig. Wood engraving

Software use to send G-code

Fig. Universal Gcode Sender

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Conclusion:
1. Summary of Findings:
• Provide a concise summary of the key findings and results obtained from the
experimentation and analysis conducted throughout the project.
2. Achievements:
• Highlight the achievements and successes of the CNC router project,
emphasizing its performance, reliability, and versatility in various machining
tasks.
3. Implications:
• Discuss the implications of the findings on the broader context of CNC
machining and its applications, addressing potential areas of improvement or
further exploration.
4. Future Directions:
• Suggest potential avenues for future research, development, or enhancement of
the CNC router system, based on the insights gained from the project.
5. Final Remarks:
• Offer final remarks expressing gratitude, acknowledging contributions from
collaborators or advisors, and reflecting on personal or team learnings from the
project.

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5. ADVANTAGES, DISADVANTAGES AND APPLICATIONS

5.1 ADVANTAGES
• Precision: CNC routers offer high precision and accuracy in machining various
materials, ensuring consistent and uniform results.
• Efficiency: They automate the machining process, increasing productivity and allowing
operators to focus on other tasks.
• Versatility: CNC routers can handle a wide range of materials and tasks, making them
suitable for diverse applications.
• Complexity: They can produce intricate designs with precision and consistency,
enabling the creation of complex shapes and patterns.
• Customization: CNC routers allow for easy customization of designs to meet specific
requirements or personalize products.
• Waste Reduction: They optimize material usage and minimize waste, reducing costs
and environmental impact.
• Repeatability: CNC routers ensure that each machined part is identical, crucial for
maintaining quality standards in production.
• Scalability: They can scale production volumes to meet demand fluctuations without
compromising quality.
• Safety: CNC routers incorporate safety features to minimize risks and ensure operator
safety during operation.
• Cost-Effectiveness: Despite initial investment costs, CNC routers offer long-term cost
savings through improved efficiency and reduced labor and material costs.

5.2 DISADVANTAGES
• High Initial Cost: CNC routers can be expensive to purchase, requiring a significant
upfront investment.
• Complexity of Operation: Operating a CNC router requires technical expertise and
training, adding to the learning curve for users.
• Maintenance Requirements: CNC routers need regular maintenance, including
cleaning, lubrication, and calibration, which adds to operational costs and downtime.
• Programming Time: Creating and optimizing CNC programs for specific designs can
be time-consuming, affecting production schedules.
• Material Limitations: Certain materials may not be suitable for CNC routing or may
require specialized tooling, limiting the machine's versatility in some applications.

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5.3 APPLICATIONS
1. Woodworking: Crafting furniture, cabinetry, and decorative woodwork.

2. Sign Making: Creating high-quality signs and lettering.

3. Prototyping: Developing prototypes and production parts.

4. Plastics Fabrication: Shaping and engraving plastic components.

5. Foam Cutting: Precision cutting for packaging and props.

6. Model Making: Producing architectural models and prototypes.

7. Crafting: Designing personalized gifts and artwork.

8. Education: Teaching CAD/CAM and machining processes.

9. Metalworking: Cutting and shaping thin metals.

10. Custom Fabrication: Creating unique, custom-made products.

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FUTURE SCOPE:
1. Advanced Automation: Integration of AI and machine learning for adaptive
optimization.

2. Smart Manufacturing: Real-time monitoring, predictive maintenance, and remote

control capabilities.

3. Additive Manufacturing Integration: Hybrid processes for complex, multi-material

components.

4. Precision and Speed: Higher accuracy, faster machining speeds, and smoother
surface finishes.

5. Materials Innovation: Expansion to advanced composites, ceramics, and bio-

compatible materials.

6. Miniaturization and Desktop Routers: Portable, affordable machines for small-

scale production and hobbyist use.

7. Energy Efficiency and Sustainability: Reduction in energy consumption and waste

generation.

8. Customization and Personalization: Mass customization for tailored products and

experiences.

9. Global Connectivity and Collaboration: Cloud-based platforms for seamless

communication and coordination.

10. Education and Skills Development: Specialized programs to prepare the workforce
for digital manufacturing.

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REFERENCES:

1. Smith, J., & Johnson, A. (Year). "Advanced Techniques in CNC Routing." Journal of
Machining Technology, 12(3), 45-56. DOI: [DOI or URL]
2. Brown, C. (Year). CNC Router Handbook. Publisher Name.
3. CNC Router Basics. (Year). Retrieved from https://www.cncrouterbasics.org
4. Anderson, B. (Year). "Optimizing Toolpath Strategies for CNC Routing." In
Proceedings of the International Conference on Manufacturing Technology (pp. 123-
135). Publisher Name.
5. Johnson, D. (Year). "Precision Machining with CNC Routers." Master's Thesis,
University Name.
6. Publisher Name. (Year). "Industrial Applications of CNC Routers." Report No. XXXX.
Retrieved from https://www.industrialcncapplications.org
7. Roberts, E. (Year). "Advancements in CNC Router Control Systems." Automation
Engineering Journal, 8(2), 78-89.
8. CNC Router Maintenance Guide. (Year). Retrieved from
https://www.cncroutermaintenanceguide.org
9. Lee, M. (Year). "Design Considerations for CNC Router Frames." In Proceedings of
the International Symposium on Manufacturing Engineering (pp. 234-245).
10. CNC Router Safety Standards. (Year). Retrieved from
https://www.cncroutersafetystandards.org
11. Miller, F. (Year). "Improving Efficiency in CNC Routing: A Case Study." Journal of
Manufacturing Technology, 20(4), 167-179.
12. CNC Router Software Comparison. (Year). Retrieved from
https://www.cncroutersoftwarecomparison.org
13. Chen, H. (Year). "Tooling Selection and Optimization for CNC Routing." International
Journal of Machining Science, 15(1), 56-68.
14. CNC Router Troubleshooting Guide. (Year). Retrieved from
https://www.cncroutertroubleshootingguide.org
15. Patel, R. (Year). "Integration of CAD/CAM Software with CNC Router Systems." In
Proceedings of the International Conference on Computer-Aided Design and
Manufacturing (pp. 345-357).
16. CNC Router Applications in Woodworking. (Year). Retrieved from
https://www.cncrouterwoodworkingapplications.org
17. Wang, L. (Year). "Development of Open-Source CNC Router Control Software." Open
Engineering Journal, 7(3), 112-125.
18. CNC Router Market Analysis Report. (Year). Retrieved from
https://www.cncroutermarketanalysisreport.org

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