CNC Electronics
CNC Electronics
Embedded Files
May 1st 2025 - August 16th 2025
During my time at Fire Risk Alliance (FRA), I had the opportunity to lead a team of interns in the full design and development of a custom CNC router control system. This encompasses both hardware and software integration as well as the mechanical design and fabrication of the system’s physical enclosure. This project not only strengthened my electrical engineering and embedded systems skills, but also provided valuable experience in project management, technical leadership, and cross-disciplinary collaboration.
Below, you’ll find an in-depth breakdown of the project’s three key phases.
To the left is a custom-designed enclosure that I developed to integrate and protect all major components of the CNC router control system, including the power switches, PCBs, indicator LEDs, and LCD user interface. The enclosure was modeled in SolidWorks, designed for ease of access and serviceability, and fabricated from durable materials to withstand the heat, vibration, and debris typical of CNC environments. Internally, cable routing and connector placement were optimized for both electrical safety and aesthetic organization, ensuring a clean, professional layout.
The core control PCB, shown in the schematic below, is built around an Arduino Nano microcontroller, which serves as the central processing unit for the entire system. Connected to the Nano is a thermocouple breakout board, responsible for accurately monitoring the spindle and cutting-fluid temperatures to prevent overheating and ensure consistent performance. Real-time temperature data is displayed on an LCD interface, allowing operators to monitor system health at a glance.
The board also includes PWM outputs used to regulate two independent pumps: one for cutting fluid delivery and another for directed air cooling. This dual-pump design allows the operator (or automated logic) to dynamically adjust flow rates depending on material type, tool load, or thermal conditions. The PWM-driven approach ensures energy-efficient and precise control, while minimizing component wear compared to traditional on/off systems.
In addition to the functional circuitry, I also designed and implemented proper electrical isolation, grounding, and wire management within the enclosure to reduce noise interference from high-current motors. The integration of modular connectors and labeled terminal blocks simplified troubleshooting and future upgrades—key considerations for both safety and maintainability.
Overall, this project combined mechanical design, electrical engineering, and embedded programming, showcasing a full lifecycle of engineering development—from schematic capture and enclosure design to wiring, assembly, and system testing.
The custom Arduino code developed for this system manages both real-time process control and operator feedback through an integrated LCD display interface. Written in the Arduino IDE, the program continuously reads temperature data from a thermocouple sensor and dynamically adjusts two PWM-controlled pumps — one for cutting fluid and one for air cooling — to maintain optimal thermal conditions during CNC operation.
The LCD screen provides live output of the system’s performance, displaying both power percentage (%) and flow rate (L/min) for each pump. These metrics update in real time, allowing the operator to monitor system efficiency and make manual adjustments if needed.
A built-in automatic safety override is implemented to protect both the tool and hardware from overheating. If the thermocouple detects a temperature above a defined threshold, the system immediately triggers an override mode, forcing both pumps to operate at 100% duty cycle until the temperature returns to safe levels. This logic ensures uninterrupted cooling performance and safeguards against potential thermal damage.
Additional features include:
Startup initialization routines for sensor calibration and LCD setup
Fail-safe logic in case of sensor disconnection or invalid readings
User-configurable parameters (temperature thresholds, PWM scaling factors, etc.) for easy tuning and adaptation to different CNC materials or cutting environments
This firmware integrates sensor feedback, actuator control, and user interfacing into a single embedded system, demonstrating a practical application of closed-loop control, safety automation, and embedded UI design.
To ensure both safety and operational efficiency, I designed and constructed a fully enclosed 8' × 8' × 6' CNC router enclosure. The enclosure was built to contain debris, noise, and cutting fluid while maintaining a clean, well-lit workspace for both operators and observers.
The structure was framed using reinforced aluminum extrusion and polycarbonate panels, providing high visibility and durability while minimizing weight. Clear side panels allow visual monitoring of the machine during operation without exposing users to airborne particles or coolant spray.
For improved usability and maintenance, I integrated LED lighting strips along the enclosure’s upper frame, delivering uniform illumination across the entire work area. This not only enhances visibility during tool changes and calibration but also improves safety during extended machining operations.
A swiveling vacuum hose system was also mounted to the enclosure, designed to automatically follow the toolhead’s movement and efficiently collect chips and dust at the source. The swivel mechanism allows the hose to articulate freely in multiple directions, preventing drag or interference with the machine’s motion. The vacuum system connects to an external dust collector via quick-disconnect fittings, allowing for easy servicing and clean material transitions between machining sessions.
This enclosure project combined mechanical design, ergonomic layout, and safety engineering principles, resulting in a clean, modular workspace that significantly improved CNC performance, noise reduction, and operator comfort.
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