LaboFlex: the world of 3D prototyping

The Colinbus LaboFlex 30/HF is the first commercially available machine that can produce precise PCBs as well as full-fledged 3D models. With its incredible resolution of 0.23 µm, high working speed and spindle with micron-level accuracy, this machine is unique.

This is a true in-house prototyping machine, which can be used to produce not only PCBs but also entire devices. This makes it an ideal machine for every design and development department.

It is also available with an automatic tool changer − click here for the LaboFlex Pro.

Make full-fledged prototypes in your own lab

Millions of designers everywhere in the world spend their time developing new products. This usually involves some sort of enclosure containing electronic and mechanical components. The development department is dependent on suppliers for each of these components. In many cases, the main sources of irritation are long waiting times, incorrect deliveries, and expensive services. The end-to-end time for product development in this manner can amount to several months, or sometimes well over a year.

The Colinbus LaboFlex enables you to produce precise components, 3D models and PCBs, all with the same machine, so you can build a complete prototype without the aid of outside sources. This makes it possible to reduce the overall development time to a few days.

Special features

• Unique controller for 3D modelling as well as PCB milling

  Due to the demanding nature of their tasks, LaboFlex machines must be equipped with state-of-the-art electronics. Fabrication of UFP printed circuit boards already requires a lot of computing power, but when this is combined with 3D modelling, only the best is good enough. Development of the embedded software required several years of effort, but it is now unique on the market.

• Elevated Z axis and removable engraving head

  LaboFlex machines have an elevated Z axis with a height of 70 mm. This provides sufficient room for making 3D models without sacrificing the stability necessary for making PCBs with extremely fine features. The engraving head can easily be removed for fast changeover between the different tasks.

• Zero backlash

  Quality milling machines are driven by precision leadscrews, but this is not good enough for milling faultless PCBs. These leadscrews have a small amount of play (backlash) in the micrometre range, which is unacceptable for milling FP circuit boards. For this reason, all Colinbus CPR and LaboFlex machines are equipped with a patented drive system.

• Flat-milled T-slot table

  An essential condition for the fabrication of high-quality products is that the workpiece is held firmly in place. For this reason, LaboFlex machines are equipped with a flat-milled T-slot table. Optional accessories and fixtures can be mounted on the table. The table has built-in, adjustable ‘mirror line’ for making double-sided circuit boards. This makes it easy to turn over the circuit board while maintaining precise alignment.

• Milling depth adjustment with micron accuracy

  Accurate depth adjustment is important in the engraving of fine letters, and it is indispensable in milling printed circuit boards. For perfect results, the milling cutter should follow the surface of the material, and the milling depth must be adjustable at the micron level. To provide this capability, Colinbus developed a driven Z axis that completely fulfils this requirement and is fitted with a vortex dust extraction system.

• 60,000-rpm, high-precision spindle motor

  The precision of the spindle motor is more important than high motor speed. When you are milling isolation traces with a width of 80 µm, even the slightest play in the spindle axis will cause unacceptable results. For this reason, Colinbus uses spindle motors with specially selected ceramic bearings. The manual motors are fitted with a convenient button for easy tool changing.

• The best software on the market

  The LaboFlex is supplied with three software packets: ColiDrive (which provides the user interface for operating the machine), ColiLiner (which supports PCB fabrication), and a professional 3D CAM package. Thanks to these three software packages, the LaboFlex is extremely easy to use. Instead of working with arcane CNC code, you work in a clearly defined visual environment where all preparatory activities and operations are intuitive.

Special built machines

The LaboFlex machines are also available in more rigid construction. They have the same precision but have a stronger spindle motor and stronger drive motors.

It is also available with an automatic tool changer − click here for the LaboFlex Pro.

	Colinbus LaboFlex 30/HF	Colinbus LaboFlex 60/HF
Item number	COLM0033	COLM0036
Working area	X 278/ Y 360/ Z 70 mm	X 400/ Y 600/ Z 70 mm
Clamping area	X 415/ Y 530 mm	X 540/ Y 770 mm
Resolution	0,23 µm	0,23 µm
Repeatability	1 µm	1 µm
Drilling speed	160 holes per minute	160 holes per minute
X/Y drives	Hybrid motors	Hybrid motors
Z drive	Hybrid motor	Hybrid motor
Spindle motor	60,000 rpm, software-controlled	60,000 rpm, software-controlled
Machine table	Flat-milled T-slot table	Flat-milled T-slot table
Tool changing	Manual with convenient pushbutton	Manual with convenient pushbutton
Tool holder	1/8" standard; others available as options	1/8" standard; others available as options
Engraving head	With micron-level depth adjustment	With micron-level depth adjustment
Dimensions	W 440/ D 585/ H 390 mm	W 560/ D 825/ H 390 mm
Weight	40 Kg	55 Kg
Power	115/ 220V, 50 - 60 Hz	115/ 220V, 50 - 60 Hz
Included software	ColiDrive/ ColiLiner/ 3D CAM	ColiDrive/ ColiLiner/ 3D CAM
Optional accessories	Vacuum table, camera, sound enclosure, milling head lamp	Vacuum table, camera, sound enclosure, milling head lamp

The complete process from the CAD drawing to the finished prototype

The printed circuit board and the enclosure are designed using a CAD package, and then a CAM package is used to generate all the tool paths. The LaboFlex makes the printed circuit board, the enclosure, and any other mechanical parts as necessary. The printed circuit board is assembled (the components are fitted and soldered), the enclosure is spray-painted, and everything is put together. The first true prototype is now ready, and it can be sent to the various departments for testing and approval. The entire project can be completed within a few days, instead of waiting weeks or months for external suppliers.

Software: powerful and user-friendly

The LaboFlex machines are supplied with three power software packages: ColiDrive, ColiLiner, and a CAM package for 3D modelling. They collectively form an integrated whole and make the LaboFlex a powerful tool for every development department or lab.

ColiDrive is the Colinbus user interface. It makes working with a Colinbus machine easy. This intuitive tool enables you to operate a machine without knowing anything about G-code or any other form of machine mumbo–jumbo. Everything is done visually, including placement of the material to be machined as well as importing and positioning the drawing. The only other thing you have to do is to press the Start button.

However, professional users also enjoy working with ColiDrive, because it’s equally possible to work with direct code import or a combination of the two methods. This means that there are practically no restrictions, and people will all types of professional backgrounds feel comfortable with the machine.

ColiDrive enables you to do more than just import drawings and operate the machine. For example, you can mill shapes or drill holes without using a CAM package or writing a single line of code. The powerful database integrates all the packages in the group and monitors tool wear. The Project Explorer keeps track of all the data of an imported file, so you always know exactly which machining operations have been performed.

Additional ColiDrive capabilities::

• Importing G-code with automatic detection of positive and negative coordinates.
• Direct input of all True Type Fonts present on the computer, which can be milled without any involvement of a CAM package.
• Visualisation of the machining operations with colour-coded milling depth.
• Machining operations can be interrupted at any desired place or time in order to perform another job, after which you can continue from where you left off.
• An integrated obstacle database where you can enter any desired shape anywhere on the machine to create a protected area.
• Dozens of optimisation functions that dramatically accelerate machining operations.
• Remote support for the software and the machine puts an end to long telephone calls and e–mail ping-pong.

Internationally unique

ColiLiner is one of the most powerful contour generators available anywhere. It imports the designs you produce using your favourite drawing package and displays them on the screen. Contouring of the various layers is performed automatically.

No restrictions

Unlike other packages, ColiLiner can process very complex PCBs with or without large copper areas. The package can easily read in commonly used file formats, including Gerber, GerberX, and Excellon. Traces and islands can be isolated in various manners. Editing options, step-and-repeat, mirroring, rotation, and many other capabilities are standard features.

CAM station

ColiLiner is more than just a contour generator: it is actually a sophisticated CAM station. You can fully adapt the imported design. For example, you can modify trace widths or separations and enlarge or shrink islands and holes.

CAD module

You can design simple PCB layouts and front panels directly in ColiLiner. This capability is highly appreciated for designing HF PCBs. ColiLiner works with True Type fonts, which gives you potent engraving options.

Design Rule Check

Rigorous design rule checking ensures that your design can be processed, and database management gives you complete control over the tools and parameters. The file that is sent to the machine contains all the information necessary for stand-alone machining. No additional machine settings are necessary.

General overview

• Imports
  • Gerber RS274X & Gerber 274D
    • Negative polarity plot files
    • Polygon definition
    • Full macro support
  • HPGL
  • Excellon 1 & 2, simple and extended version
• Exports
  • Colinbus Binary Format (BFF)
  • ISO G-code
  • 274NGC G-code
  • HPGL
• General Features
  • Design rule check for any tool
  • Up to 4 different tool types for insulation and copper removal
  • Full featured, unlimited tool database
    • User can own tools
    • Tool life monitoring
    • Tool preview
  • 2 different tool types for board cutting
  • Multiple contouring modes
    • Smart contouring - uses most suitable tools for fastest processing time
    • Contour smoothing
    • Seperate settings for insulation thickness with smaller tools
    • Adjustable overlap of tool paths
    • Remove all copper on negative polarity plots
    • User defined step for contouring pads multiple times
  • Tool path optimization
  • Multiple modes for copper removal
    • Parallel
    • Expanded
    • Mixed
    • Meander
  • Supports plated and non plated holes
  • Quick change of aperture and drill sizes (individual objects or groups)
  • Editing features
    • Creating
      • Lines
      • Polygons (Filled and empty)
      • Polylines
    • Delete
    • Copy
    • Move
    • Rotate
    • Mirror
    • Scale
    • Step and repeat
    • Supports all true type fonts and has a special
      vector font
    • All these features applies for all layers, also
      contour layers
  • Measuring tool for point to point measuring
  • Can transfer elements between layers
  • User defined copper removal area
    • Whole board
    • Rectangle area(s)
    • Circle area(s)
    • Polygon area(s)
  • Separated layer contouring or All-at-once contouring
  • Any object on screen can be milled on line or around
  • Text can be milled on line or around
  • Monochrome and color printing support
  • Can highlight pads
  • Toggle modes for showing contours and/or tracks in
    true size or as hairlines
  • Can work in Inches or in Millimeters
  • Quick features to align misaligned layers, can align
    layers to:
    • Pad center
    • Object center
    • Element boundary
    • Element center

General

The purpose of ColiCAM software package is to calculate and generate toolpaths for machining of various objects on milling machines.

Source data for calculation and generation of toolpaths are drawings of objects to be machined. These drawings are usually created with help of various CAD software packages. One of such packages is AutoCAD from Autodesk. For farther processing by ColiCAM, the completed drawings have to be exported to a disk file in one of supported data formats. The task of exporting graphics of the drawing is usually a part of CAD software.

Current version of ColiCAM may import drawing images in following formats

• Autodesk Drawing Exchange Format (DXF)
• Hewlett Packard Graphic Language (HP-GL)

The procedure for generating of complete machining program consists of following steps:

• Import of drawing image in one of supported formats (DXF or HP-GL)
• Optional editing of imported drawing − for example it may necessary to remove redundant graphical elements or interactively close selected open shapes
• Setting up general parameters like stock dimensions, preferred origin of coordinates and eventually default machining parameters
• Creating machining geometries by selecting shapes from imported drawing
• Defining toolpaths by selecting required tools from Tool Database
• Applying machining strategies and setting up individual machining parameters for each defined toolpath
• Ordering program to calculate trajectories for defined toolpath
• Output (to a disk file) of resulting machining program in the format accepted by milling machine

Current version of ColiCAM may output machining programs in one of following formats:

• Generic
• RS274GC G-CODE
• Basic ISO CNC code
• Hewlett Packard Graphic Language (HP-GL)

Project database

ColiCAM stores all information about machined object in project database that at any stage can be saved to disk file. Internal precision (minimal unit) of the database is 1/100000 mm. Coordinates and sizes are stored with this precision. Angular values are stored with precision of 1/1000 degree. The software can process drawings with maximal size of 4400 by 4400 millimeters.

Project Database consists of imported drawing, selected geometries and calculated toolpaths trajectories. This information is presented graphically on computer screen. Project Database includes also numerical data. These data are several types of parameters that are set while preparing machining program for output. Current parameters’ settings are presented (and may be at any timed modified) in tabular form on various pop-up dialogs.

Diagram below presents the structure of ColiCAM project database:

Machining strategies

Algorithms applied to calculation of toolpath trajectories depend on topology of shapes transferred to geometry and selected machining strategy.

Following machining strategies are available in ColiCAM:

• FACE − used to take out material to specified depth over whole surface of the stock.

• PARALLEL − used to take out material to specified depth within boundaries of closed shapes or between boundaries of the stock and boundaries of closed shape inside the stock. This strategy is always combined with PROFILE as then next step in order to finish outline of the take-out.

• SPIRAL − used to take out material to specified depth within boundaries of closed shapes. Toolpath trajectory for this strategy is calculated is such way that finishing outlines with PROFILE is not necessary.

• PROFILE − used to cut out outline of closed shapes internally or externally.

• SLOT − to cut along outlines of shapes (closed and open) with or without offset of ½ of tool diameter.

• STROKE FILL − used for taking out material in parallel strokes within boundaries of closed shapes. This strategy is usually applied for machining shapes constructed as strips.

• DRILL − drilling holes

Editing function

Imported drawings are not always suitable for extracting geometries for machining. To solve that problem ColiCAM provides a set of advanced features that allow editing imported drawings. Editing functions tools enable to relocate and transform shapes. There are also functions for constructing shapes for machining from elements of other shapes. Apart from operating on imported shapes, new shapes may be manually added to drawings.

Editing functions can be therefore treated as simple CAD system integrated within ColiCAM. Using these functions the user can actually create drawings of object to be machined directly in ColiCAM, without necessity to import drawings generated by other CAD packages.

Documenting features

Saved to disk project database and generated machining programs are not the only outputs from ColiCAM. Working session may be documented in other three different ways:

• Contents of graphic screen may at any time copied to Clipboard and then pasted as bitmap to other documents
• Project may be printed in any scale on a color or black & white printer
• Build up of machining programs may be stored in plain text file and presented in Notepad