Bottom Brick Body

In the design workspace, hide the top brick body from the Browser panel.

Click on the eye icon to show/hide bodies in the Browser panel.

We'll begin milling the bottom side of the 2x4 bricks first.

Setup Stock for Bottom Side

In the manufacturing workspace, create a new stock setup.

Click on the bottom left, upper stock point of the bottom brick model.

Select the stock tab and enter 0 for the stock side offset and stock top offset.

Click OK when finished.

Bottom Contour Settings

Click on the 2D contour icon in the 2D Milling Menu.

Select the 1/8in flat end mill under the tool section.

Update the values in the spindle speed, cutting feed rate and plunge feed rate.

Select the Geometry tab and select the bottom outline of the of the 2x4 brick, it should be highlighted in blue.

Under the Passes tab, enable Multiple Depths and enter 1mm into the Maximum Roughing Step down text field.

Click OK when finished.

Bottom Pocket Settings

Click on the 2D Pocket icon in the 2D milling menu.

Select the 1/16in flat end mill under the tool section.

Update the values in the spindle speed, cutting feed rate and plunge feed rate.

Select the Geometry tab and select the surface on the 2x4 brick highlighted in blue.

Under the Passes tab, disable Stock to Leave and enable Multiple Depths.

Update the value in the Maximum Roughing Step down text field.

Under the Linking tab, update the ramp clearance height text field.

Click OK when finished.

Contour Pattern

In the Browser panel, right-click on the 2D contour and select Add to New Pattern.

Under the Direction 1 section, select the X axis or a line edge on the bottom brick body.

Update the Spacing for Direction 1 and the Number of Instances 1.

Enable Additional Direction.

Under the Direction 2 section, select the Y axis or a line edge on the bottom brick body.

Update the Spacing for Direction 2 and the Number of instances 2.

Click OK when finished.

Post Pattern GCode

In the Browser panel, right-click on the Pattern of the contour operation and select Post Process.

Select Bantam Tools in the Post section.

Enter a file name in the name/number text field under the Program section.

Click on the folder icon under the Output folder section and choose a desired location to save the file. 

Click Post when finished.

Repeat this process for the Pattern of the pocket operation.

Pocket Pattern

In the Browser panel, right-click on the 2D pocket and select Add to New Pattern.

Under the Direction 1 section, select the X axis or a line edge on the bottom brick body.

Update the Spacing for Direction 1 and the Number of Instances 1.

Enable Additional Direction.

Under the Direction 2 section, select the Y axis or a line edge on the bottom brick body.

Update the Spacing for Direction 2 and the Number of instances 2.

Click OK when finished.

 

Bantam Tools Plan Setup

In the Bantam Tools software, click on the initial setup icon.

Click Open File and select the contour pattern gcode file for the bottom brick.

Select the 1/8in flat end mill from the T1 dropdown menu in the milling tool section.

Click on the plan setup icon. Under the gcode file, add a 1mm value to the X and Y text fields in the Plan Offset section.

Repeat this process for the pocket pattern gcode file.

Be sure to select the 1/16in flat end mill when setting up the milling tool section.

Milling Bottom Bricks

The 1/8in flat end mill should already be installed. Your stock material should be 11.5mm thick and secured to the spoil board.

When ready, click on Mill Single File for the contour pattern gcode file.

When the milling job is complete, run through the Clean-Up Wizard process.

After cleaning, proceed to install the 1/16in flat end mill.

Proceed to click on Mill Single File for the pocket pattern gcode file.

When the milling is complete, run through the Clean-Up Wizard once again.

Proceed to remove the bricks from the spoil board.

Finish Bottom Bricks

Use sand paper to remove any rough edges and burs.

Test Fit Bottom Bricks

The bottom bricks should fit onto standard LEGO base plates and bricks.

In the next page, a LEGO base plate is used as a jig holder to mill the top side of the bricks.

This guide was first published on Jun 15, 2022. It was last updated on Jun 15, 2022.

This page (Milling Bottom Sides) was last updated on Aug 12, 2022.

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