(moved) dremel milling toolhead for RepMan

by MarcusWolschon, published

(moved) dremel milling toolhead for RepMan by MarcusWolschon Jan 29, 2010


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This is an alternative toolhead to allow milling with a RepMan 3d printer.
Feel free to adapt it to other printers like Mendel, Darwin and Makerbot.
It should work fine for milling 3d-objects (Skeinforge) and PCBs (visolate) or for exact drilling (drill holder attachment) and cutting (90° attachment and cutting-disc).

You need a Dremel Flex Shaft Attachment (Model 225) and a Dremel as well as an M5x95mm(or longer) screw or threaded rod for this.

Documentation: http://www.bitsfrombytes.com/wiki/index.php?title=Milling#milling_PCBs
Forum-Thread: http://www.bitsfrombytes.com/forum/post/milling-toolhead-o-thingiverse
(I used http://www.bitsfrombytes.com/forum/post/3d-model-toolhead-attachment-design-alternative-heads )

Update: I made a Video (http://www.youtube.com/watch?v=aOt_yXAkMrs) of my first tests of PCB milling using this toolhead. It performed well given that I fitted a way too large milling-bit and did not tighten/block the springs holding the print-surface.
Update: Experimental Skeinforge settings for milling are documented here: http://www.bitsfrombytes.com/wiki/index.php?title=Milling#milling_in_3D
Video: http://www.youtube.com/watch?v=7rdkIjtuiYA

(Details: http://www.bitsfrombytes.com/wiki/index.php?title=User:MarcusWolschon/Challenges )
Get 10 small mendel parts or 2 larger ones or your design printed for
adapting this RepMan Dremel milling-toolhead to fit the Mendel.

Note that you will probably have to design a new x-carriage-lower_1off or even also a x-carriage-upper_1off due to the poor design of the Mendel x-carriage regarding mounting alternative tools that are wider then 22mm.
5 additional small or 1 large parts if you can do it so extruder and mill can be switched with 4 or less easily accessible screws.


  1. print it
  2. remove the collet nut and collet
  3. insert the Flex Shaft into the toolhead, turn it to move the black threading through the opening at the end.
  4. re-attach the collet and collet nut, thus fixing the Flex Shaft in place.
  5. replace part 10056 of your RepMan with this toolhead, leave the extruder attached to the electronics or attach a resistor of 100KOhm(840 to 920) to identify this as a router. (http://rapmanv3.blogspot.com/2009/06/machinefirmware-manual.html)
  6. attach the long M5 screw to touch the Z endstop at the correct height for the milling tool you inserted into the Flex Shaft.
  7. Have fun!

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Hello , I wanted to know which program generates the kss file.

I usually use the kisslicer and then charge the kss file in the pronterface . But I find no program to replace the kisslicer to generate a kss file but function as 3D milling machine.

Greetings and Thanks

There are no KSS files.
In fact, there are not ANY files on Thingiverse anymore.

This looks good, but the STL seems to be a bit broken. Is there an STL without the holes and extra funny bits?

That thing was made in Blender a long long long time ago.

No, there is not.

Back then it skeinforged and printed fine.

(The only one I ever made in blender. Gave it up afterwards.)

If you can repair it or use the meassurements to construct another one
(this one follows the curve of the flex-shaft very well to reduce any shaking),
please tell me. So I can link to it.

Tried printing this with RepG28 and Skeniforge35 @ 0.32mm layers and yes the model and gcode did look "broken" but it printed reasonably OK. There are a few (8-10 at a guess) single layer thick planes inside the top of the cone, the first 3 of which can be easily removed with a scalpel/knife and the rest of which can be reasonably easily removed using a dremel with the brown tapered grinding stone. Once cleaned up this fits the dremel extension very well!

I made a video
lt;iframe width="560" height="349" src="http://www.youtube.com/embed/z14gkPYD0aI?rel=0http://www.youtube.com/embed/z...
amp;amp;hd=1" frameborder="0" allowfullscreen

about using this in a Thing-o-Matic using a toolhead-adapter.

Very cool! You should talk to @roboteernat, he's converting his Makerbot to do CNC milling for small PCBs too!

By now a few other people have tried this head and it just works like a charm. :)
3 screws are all that is needed to switch between extruding and milling on a RepMan.

Trust me this thing's got issues.

Ok, I tested the gcode visolate 2.1.4 generated with a pen and it was good.
The smallest engraving-tip I could find was 1.6mm but I found wolfram-carbite engraving-tips
that are conical and very fine. They should do well for the PCB.

Now I
´ll add a feature to set the head-speed in visolate 2.1.5 and test it out on a real
PCB in the next days.

Are you using Tungsten Carbide cutter (9903, 9901) for routing the pcb?

I have also modelled a dremel toolhead but I wanted attaching the main dremel (you posted your design yesterday, when I was half-done).

I will post my version (its for Rapman too) in the next days.

Thank you for your design!

Sorry, 9901 and 9902 should be the correct dremel part number.

For the first test I just grabbed the first cutter I could find in the box.
I don
´t know what cutters work best. It does not have to be very very strong.
But it probably needs the finest tip I can get. In the shop I saw that Dremel/Bosch
has come up with quite a lot of new cutters for 2010.

I´m up for suggestions. ;)

With permission of the original author I just moved Visola
te to
and am starting to improve it to generate gcode compatible with
the RepMan firmware 1.0.5 and later.