Inlay App - Puzzle pieces not fitting

Easel Easel Pro
1

So…I got about 80 orders for custom puzzles this Christmas season. Until last week everything was going fine. Now all of a sudden my pieces aren’t fitting…at all…not even close.

I’m carving the same shapes essentially over and over again and using the same fonts. My bit is always set to 1/8 (.125) and my tolerance is 3 times the max amount so 0.03.

Can someone tell me why this isn’t working all of a sudden?

Thanks!

2

It may be that your machine has slipped out of calibration. It may also be that your bit is off from 1/8th. This might happen if you suddenly got a new source of bits. If the bit is larger than expected, your pieces will fit loose and if it is smaller your pieces will be too tight.

I recommend the following…

  1. Use Easel to design a rectangle that is 1 inch by 2 inches.
  2. Cut this rectangle out by cutting ON THE LINE and not inside or outside.
  3. Measure the short side and the long side with calipers. Call the measurements S and L.

Your bit’s cutting diameter will then be 2 times S minus L and your machine’s inch value will be L minus S.

If L minus S is bigger than an inch, you will need to adjust your steps to get it in proper calibration. If your bit is smaller than expected (2 times S minus L is bigger than 1/8th) then you need to tell Easel the actual bit diameter or your pieces will fit too tightly.

3

Any sudden change in output strongly indicate something “suddenly” changed or gave way. Look over the set screws on all pulleys etc, secure with Loctite if they havent been already.

I have seen reports of pulleys with some slippage (wiggle a fraction of a revolution, on the shaft) which may be hidden from plain view.