New Build: Pimped-Out Shopbot PRS Alpha 60x96 w/ATC

[Adaptel]

I set out this past winter itching for a project to tackle, and I wanted to build a CNC router that was at least 48x96”. I had a budget of $15K and wanted to see just how much of a machine I could put together with this. Now that I have nearly finished this build, I must say that I a quite pleased and surprised with what I ended up with. The biggest challenge I faced was finding a decent, accurate, rigid machine design that could be disassembled because this machine would have to fit into my basement with limited door access. The whole project started when I found a used Shopbot PRS Alpha machine that was being sold at an auction in Wisconsin which I won for only $3,500. It turned out that this machine was from around 2007, was purchased for a high school shop program, and the machine was only used to make a couple of cuts (for reasons I don’t understand). It was practically new but since I live in New England, this meant ROAD TRIP! The only thing I didn’t like about the shopbot was the control system which was proprietary, used non-standard G-code, and was limited as far as expandability and flexibility. I looked at them all and decided to power this router using CNC12, which I knew little about, but turned out to be a great choice.

My wife and I flew to Wisconsin, rented a minivan, and somehow we were able to break this very LARGE machine down and fit it inside the van with no room to spare. After a winter of some long nights in the basement, fabricating, waiting for parts, and utilizing some clever backyard engineering….below are some specs on my CNC. Be kind because I am only a hobbyist and have no formal experience with CNCs….but I am pretty happy with what I ended up with.

• Shopbot PRS Alpha PRS3 60x96 table with closed loop Oriental Motor servos and controllers. I used the OEM drive system because it met all the specs for my needs. I just needed to make some custom interface cables to connect the controllers to the Acorn board.
• Centroid Acorn controller with ETH1616 input/output expantion board and wireless pendant
• 7.5kW Chinese ATC spindle with 15-tool fork-type rack
• Lasertree 30W diode laser with pneumatic deployment and built in crosshair alignment laser
• Stepcraft OTK-3 Tangential Knife with pneumatic deployment
• Logitech Streamcam 1080p webcam (for use with the exiting new Paper Tools system)
• Five-zone vacuum hold down system powered by two 5kW ring compressor blowers
• Custom spindle cooling system with radiator and temperature controlled fans
• Wireless infrared touch probe located in ATC tool rack
• Custom dust collection system with dockable dust shoe, air blow-out system, and shoe presence detection
• Fixed tool height touch off device with dust removal nozzle
• USABLE WORK AREA of 60.75x96.1” WITH ABOUT 6.0” OF Z travel

I am very impressed with the Centroid Acorn system and how it has performed during my initial testing and cutting. A complete photo album of my build can be seen here on Google Photos for anyone who might be interested in seeing them.

[CentroidFrog]

What an interesting story, and a great looking machine!
Do you have plans to regularly use it for anything specific?

[Adaptel]

What an interesting story, and a great looking machine!
Do you have plans to regularly use it for anything specific?

Thanks! Yes, I plan on using it for many things including cutting EVA foam flooring for boats, cutting Sunbrella outdoor fabric for marine canvases, various hobby woodworking projects, and other things that I haven't thought of yet

[suntravel]

Cool project, and yes Centroid motion control is very smooth like a high-end industrial CNC.

Uwe

[Sword]

Awesome job, you're gonna like it! My PRS is nothing compared to yours when it comes to all the bling, but it's been working great since 2019 with CNC12!
I see you followed ShopBot's original circa 2007 Alpha wiring methodology. Sorry, had to say it, because mine was the same way.

[cnckeith]

right on! thanks for posting, great photo album!

[Gary Campbell]

You should share your post to the ShopBot and Centroid Facebook groups to inspire and encourage other SB'ers to make the swap.