The really cool part about my job is that I get to preview new things in our industry that are hitting the market, and report on them to the readers of the Slippery Rock Gazette.
Every month, it seems, I am seeing new products, tools and systems that are helping to revolutionize the way we Fabricators do our thing. One of the products that I have evaluated recently promises to be a "game changer" for a very broad segment of our market, and that product is from USG Robotics, called "VeinMatch."
From the moment I saw it, it was kind of like love at first sight. I could immediately see the potential that VeinMatch has to help Fabricators navigate through the "mine field" of laying out a slab and the pieces that will be cut from it.
What was even more exciting to me, was the fact that VeinMatch has a wide range of uses that will benefit Fabricators that not only have CNCs and WaterJets, but Fabricators that do not! This is the key element here that will make VeinMatch, in my humble opinion, a real game changer for our industry.
With this system, a guy that is making templates with a digital templating system, such as an LT55-XL, can now digitally "move the pieces" that he will fabricate out of any slabs, to match up vein movement ≠ before he cuts anything. He does not have to have a CNC or a WaterJet in order to benefit from this new and very affordable technology.
I spoke with Morgan Gansauer of USG Robotics to get clued in on the various aspects of this new software system, and had some questions that I just had to ask in order for me to fully appreciate the impact that this software will have on our industry.
The following is an informal "Q&A" on the VeinMatch software system:
Q: Morgan, in a nutshell, how does VeinMatch work and who can use it?
A: VeinMatch is very simple to actually use. We feel that anyone who can use a Windows' Paint program can use this software. All of our tool functions have buttons along the left side of the screen, but are also accessible through the toolbar or with a right-click on the mouse. These are your tool options: Select, Move, Rotate, Create Block, Break Block, Set As Hole, Set As Part, Undo, Pan, Set Alignment Mark, Delete Alignment Mark, and Snap.
The Snap tool also has a setting to allow you to offset the distance between two pieces, which is necessary to adjust for your type of machinery so that you can use common line cutting. Using the rotate tool, you can either manually turn the piece or set a specific degree like a full 180. The Set As Hole function allows you to "black out" a sink or faucet hole, giving it a much more realistic view of the final job.
Q: OK ≠ so, a guy's reading this far and wants to know, "What equipment will I need in order to benefit from using VeinMatch?"
A: When you purchase the VeinMatch software, you will still need a couple items no matter which type of cutting equipment you use.
You will need to purchase an EOS Camera and setup a grid for calibration. You will also need a computer, an A-Frame, and depending on how intricate you want to be with lighting, you might want to setup a "photo-booth," but it is definitely not necessary.
You will also need a CAD program or digital templator like the LT-55 to create your initial DXF file. We recommend the Cannon Rebel XTI as a camera due to the fact it is relatively inexpensive, takes high-quality pictures and is still EOS capable.
Once you have these items, the calibration process is simple. We recommend mounting both the camera and A-Frame in a permanent location to avoid calibrating every time you want to take pictures.
Q: But isn't VeinMatch designed for use with a CNC or other type of "robotic" machine like a waterjet or one of USG's Robocut machines?
A: VeinMatch, built initially within USG Robotics RoboCut Software, was shown to be a very useful tool amongst those who owned a RoboCut. After realizing its potential, USG Robotics decided to make a smaller program with only the necessary tool functions for those who both own a RoboCut and also for the rest of the industry.
Using a three-point alignment system, the exported files from VeinMatch can be used by anyone with a CNC saw/sawjet, waterjet, table saw or even a hand saw. For those who are using a table saw or hand saw, a printer or plotter would be needed to make the templates.
The bottom line here is that VeinMatch is designed to show what pieces will be cut, how those pieces come together to form the final job, and supplies a DXF file to allow you to cut those exact pieces.
Q: So, a guy that does not have a CNC or a WaterJet can still use this system? How do you set up your cuts if you're cutting with a regular bridge saw or a hand-operated saw?
A: To guarantee that you cut your pieces the same way they were laid out, we use "Alignment Marks." These are literally stickers that are placed on the slab.
If you currently have a laser or photographic system at your machine you will only need to place three dots which are typically placed in a triangular pattern. These alignment marks will remain on the slab through the cutting process. If you are using a hand saw or table saw, it is rare to have any laser or photo-system, so you will want to place more stickers.
If you are using a hand saw or table saw, you will need to place more alignment marks on the slab before photographing. You will have to make an assumption of the placement of pieces, meaning if you know that you will be cutting a large piece out of one of your slabs, you will probably only need the original three.
If you are planning on taking several pieces out of the slab, you will want to place enough that each piece will have two, if not three, marks in each piece. Photograph the slab in VeinMatch to create your calibrated image.
Open both your calibrated images and DXF file in VeinMatch. Place your pieces in the desired location. After all your pieces are set, you will use the Alignment Mark Tool to "tag" the stickers on the slab photograph. This tool will draw the marks into the DXF file.
Once all the marks have been tagged, you will then click save, and a DXF file for each slab used will be saved in the specified folder. Now you will send that DXF file to your printer or plotter.
When your templates are cut, the alignment marks will be cut as well. You then take those templates to the slab, align the cut marks with the stickers on the slab, mark out the pieces and cut.
Q: What about guys that already have a CNC machine or a WaterJet or a saw jet? Can this software be integrated into their existing systems?
A: If you have a laser or photo-system, this is the easiest and most straight forward method. Place three dots on each slab in a large triangle pattern. Photograph the image in VeinMatch to create your calibrated image. Open both your calibrated images and DXF file in VeinMatch. Place your pieces in the desired location.
After all your pieces are set, you will use the Alignment Mark Tool to "tag" the stickers on the slab photograph. This tool will draw the marks into the DXF file.
Once all the marks have been tagged, you will then click, save and a DXF file for each slab used will be saved in the specified folder. Send the appropriate DXF file to your machine.
Your laser will project the pieces as well as the alignment marks or your photo-system will allow you to align the marks with the stickers. Align the projected marks with the stickers on the slab, disable the alignment marks and cut.
Q: So, let's look at the guy who's getting ready to pull the trigger on buying a new or used CNC, a waterjet or a saw jet. How can he add this to his "techno-package?"
A: If you're using a CNC saw or waterjet with no laser or photo-system you will not want to place the three stickers in a large triangle pattern because you will most likely be using a 0,0 point.
Instead, place all three in the lower left hand corner. Photograph the slab in VeinMatch to create your calibrated image. Before moving the slab, take a 3 foot by 3 foot piece of clear plexiglass and set it over the alignment marks. Mark these three marks with a grease pencil. This will be your reference point jig. Open both your calibrated images and DXF file in VeinMatch. Place your pieces in the desired location.
After all your pieces are set, you will use the Alignment Mark Tool to "tag" the stickers on the slab photograph. This tool will draw the marks into the DXF file.
Once all the marks have been tagged, you will then click save, and a DXF file for each slab used will be saved in the specified folder. Open the DXF file on the machine, line up your reference jig with the three marks, offset your 0,0 and cut.
USG Robotics has the ability to retro-fit any CNC Saw/SawJet or WaterJet with its patented RoboEyes Vision System.
VeinMatch promises to be a total game-changer in our industry, and will benefit a very wide range of fabrication operations. This software has the potential to save lots of time and money in the form of getting things done right-the first time.
This will eliminate the need to ever reposition the slab to align the marks and also will allow any of these machines to operate off the RoboCut software.
Q: So, if a guy asks, "Will this run my CNC machine or my Waterjet or my saw jet?" What do you tell him?
A: VeinMatch is not designed to run any machines. It is made to do layouts. Throw out the tape measures and masking tape. Stop guessing at how two pieces will be seamed together. VeinMatch does that for you.
It will supply a DXF file with the pieces in place for the layout so that you can run your machines. One of the main ideas behind this software is that anyone can make use of it.
There is a lot of separation in our industry. We have the die-hard CNC guys, the WaterJet guys, the saw jet operators, the custom hand fabricators, the RoboCut owners, etc. This software allows all of us to be on the same page, to work with the same tool, which, in turn, creates a higher quality end product for both fabricators and their customers regardless of your preference of machinery.
Q: You mentioned before that this VeinMatch software works with the LT55 Laser Templating System. I have one of those myself. How easy will it be for me to get up and running using the VeinMatch program?
A: VeinMatch is totally compatible with the LT-55 Laser Templator from Laser Products. Tests have been run and VeinMatch is capable of being installed on their new computer system. This opens a whole new realm of possibilities for VeinMatch.
Imagine templating a kitchen for "Mrs. Jones" and being able to do a layout for her standing right there in her kitchen. Then shoot those files back to the shop via email so your guys can start cutting. If you are looking into getting a digital templator, the LT-55 is highly recommended due to the ability to finish DXF files on the machine, which eliminates the need to transfer the information into a separate CAD program.
Q: This is what I saw to be the "game changer." How does this effect the way you do your work with your customers? How does VeinMatch keep you from "stepping on a land mine," so to speak?
A: All I can really say about VeinMatch is that it has definitely changed the way we do business. We are affiliated with a fabrication shop in Illinois. We use this software on every job, even those without veining.
VeinMatch allows our CAD guys to setup the file for our operator so that he does not need to waste the time attempting to make the best use of material. He will just open the file, align the marks and cut.
In our showroom we have setup 50 TVs. When we have customers come in for layouts, we sit at the TV, have a cup of coffee and layout their job. This keeps them off the shop floor, but also helps them become comfortable and develop confidence in our company.
We can give them the answer to the most commonly unanswered question in the industry, "How is it going to look?" They can leave our shop with a picture of their countertops.
We also use a saved copy of past jobs to show our potential customers. They ask, "How will my tops look?" and you answer, "Something like this," while showing them a past job of the same or similar material. We have definitely sold customers because of VeinMatch.
As you can see, VeinMatch promises to be a total game changer in our industry, and will benefit a very wide range of fabrication operations. I see the potential this has to save lots of time and money in the form of getting things done right the first time.
You can learn more about VeinMatch by calling Morgan Gansauer toll-free at 800-999-3025 or going to USG Robotic's web site at www.usgrobotics.com
That's all for now. I've got to go do some slab layouts with my LT55-XL and VeinMatch. Actual VeinMatch screen shots show how flowing grain positioning and book-matched cuts can be achieved, with stunning results. Best Regards & Happy Fabricating!
Using USG Robotic's VeinMatch and Laser Product's LT55-XL is a hands-on subject that is taught by AZ School of Rock. For more information, contact Kevin M. Padden at www.azschoolofrock.com, by phone at 480-3099422 or via e-mail at info@azschoolofrock.com
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