Thanks for the interest and probing questions. With these aggressive claims, the invention certainly deserves it!  OK there are several misconceptions how the Dream Cutter unit is constructed and used that are apparent, certainly understandable with the limited information currently provided.   I will address some of these now, and generate more examples later for the site.

First off its important to realize that the mini-lathe version is only the first line, one that is proven in prototype testing,  yet due to its compact size presents the greatest challenges. The Mini-Lathe Dream Cutter as represented on the site now is optimized for miniature lathes. This must be considered so as to keep the potential for larger equipment in proper perspective.  The claims will apply to all sizes of Dream Cutter, however the product lines will be optimized to take best advantage of the host lathe specifications.  Later versions will be more massive, and require less hand manipulation, their look and operation will differ. We even have a servo-controlled version on the boards as well.

The Mini-Lathe Dream Cutter does perform well on its intended equipment (light, precision lathes of less that 7” swing) because we engineered the unit to match or exceed the typical mass of the mini-lathe’s parts and take advantage of unique aspects of the mini’s operation.  While substantially more complex, the Mini-Lathe Dream Cutter is near the mass of the stock compound, and it is built with positive-lock (down) pivot adjustments and brake so that the assembly fits snug and pivots smooth. Its assembly is a highly engineered, jigsaw puzzle with precise and adjustable fittings. In other words, a key design requirement was to ensure that the Dream Cutter is NOT the weakest link in the chain. It does contain a leadscrew in both of its pivots.

The primary advantage and invention of the Dream Cutter technology is the incorporation of 2 additional degrees of controlled tool freedom of movement, rotational and transverse. I use the term “compound radial” to describe the primary and secondary adjustable pivot actions of the Dream Cutter as exhibited on a lathe cross-slide saddle, in place of the traditional compound rest. Think of a cutting arc whose azimuth intersects and tracks along an over arching arc. The essential purpose of having a secondary, adjustable tool post pivot, mounted on the arm of a primary adjustable pivot is for “Compound Radial Cutting”. A technique where material de-bulking is rapidly accomplished through radial side sweeps in advance of the final cut.  In concert with aggressive plunges, this permits parting with significant reductions in tool stress.  This side sweep reduces finish cut waviness, by leveling the cut trough. Waviness is a industry standard term for a measurable effect of surface finish on machined surfaces caused by the wake of the tool path as it cuts (melts) the workpiece surface.

This side sweep action does also facilitate radial part necking and piece parting with the ability to “nibble” through any thickness or material without chatter.  You don’t even need a special parting tool as you can nibble to accommodate the tool dimensions as you part. Again your hand is on the upper control, and the operators body provides an extra layer of shock absorbing mass should a inadvertent bind or collision occur during the operation. Again an effect particular to a miniature equipment.

Another word on the rigidity of the Mini-Lathe Dream Cutter model, unlike larger versions it is important that the operator maintains control the tool (hands on the levers). This is essential during radial and taper to avoid collisions and to maximize rigidity and control of the pivot.  The operator controls the tool post with his right hand, holding the secondary (upper) lever. Twisting this knob releases / brakes the tool post pivot.  The primary pivot knob (lower) is used to control the primary pivot, with braking accomplished via the side lever. These brakes have a high degree of surface area and the assembly becomes more precise as they (positively) lock.  The lever on the left of the tool post is used occasionally and has 2 purposes: 1) Quick tool release, 2) Locks the pivot offset.

I have some diagrams to describe this Compound Radial Cutting (CRC) technique that I will try to upload.  With respect to the 3” ball claim, it is poorly worded. It should be “cuts a ball in seconds, up to 3”.  Ie a 3” steel ball would take longer than a Delrin ball, however  a small one can be accomplished in seconds with practice.  It’s a very smooth, almost single action operation.  The swarf this CRC method generates is enormous.  The bass cuts fast, however yes a 3” dia steel ball would have to be cut carefully and much slower.  HSS tools can do it though.

With respect to the video-demonstrations on the site, these are just preliminary and to demonstrate the concept employed. There are significant imperfections in this simulation representation with respect to movement, including distance pivot is offset. I had a difficult time making this from CAD. The actual max pivot offset is 3” for the MLDC (+- 1.5 from zero center).  The idea with the taper demo is to show how in concert with the saddle, one can taper for the full length. The unit does have feed screws, in both axis.  In actual prototype testing, I even applied a power screwdriver to the leadscrew knob to feed the plunge for a smooth taper cut. What I should have shown is how the unit can cut a taper in both directions, from either side of the work piece!  Versatility and obstruction clearance is a prime advantage for a rest on a mini-lathe.  This unit can taper the inside of a cup, and round the lip in a single operation.

With respect to operator skill, it can be used two ways. As a conventional compound or radius turner, its straight forward. With respect to Compound Radial Cutting, yes it requires two hands however the lathe X & Y are generally locked. The action comes quite natural and is fun. It may take some practice, however the artisans and craftsmen will quickly adapt.  I have fun with the Mini-Lathe prototype all the time, however my mitts are large and I don’t grasp the lathe knobs well so I prefer to wield the Dream Cutter on my larger lathe.

Production units are on their way in August, just met with the CNC shop this morning.  Since the initial (original) videos on youtube generated so much visibility, I am holding off showing more shots/videos of the prototype. I want to represent this new unit with its best image.  The CNC versions with laser engraving are so much nicer than my hand cut assemblies.

We will make several units of the first batch available for evaluation and review, as it’s your all opinion not ours that counts.

Website : Dream Cutter BLOG News, Lines, Support and Project Ideas sections updated.

May 2010
Mini-Lathe Dream Cutter initial production batch in progress.  
Dream Cutter LLC contracts a premiere San Diego based precision  fabricator for the initial production run.
The first batch of 100 assemblies will be ready for shipment August 1, 2010.

Pricing and availability information coming soon.
March 2010

DREAM CUTTER  ESTABLISHED AS A CALIFORNIA based LLC to promote research and sales of Dream
Cutter products and services. Dream Cutter LLC develops machine tool accessories that deliver exceptional
value by boosting the performance of legacy equipment to new limits.

MINI-LATHE DREAM CUTTER READY FOR PRODUCTION
By Peter B. Martin  

Initial development was spurred on by the many metalworking enthusiasts who wrote me with interest
in a homemade tool demonstrated on You-Tube  where the tool was coined the “Dream Cutter”,
based on the cutting action exhibited. This version of the tool was loosely based on a design
pioneered by inventor Edward F. Hausam in 1947. While effective in radial cutting certain dimensions,  
I was disappointed with the tools performance limitations with respect to work piece diversity and
operational efficiency. I envisioned a more far more capable and practical tool.  

As a home shop machinist, I frequently found myself constantly re-adjusting my lathe tail-stock and
compound to cut tapers, often several times on a single part. I considered the benefits of the common
lathe accessories including tool turrets, the quick change tool post, and various taper attachments and
the particular problems they present on bench top equipment.

This experience combined with the feedback received from you-tube afforded me the insight to
develop the design requirements for the Mini-Lathe Dream Cutter.  This includes radial and tapered
turning, parting and facing operations, maximum maneuverability, and bolt-on installation. I also
recognized that if I could solve the problem with sufficient rigidity for mini-lathe equipment certainly I
would have a scalable design suitable for more massive employment.
 
After developing and proving individual features, they were implemented as integrated prototypes for
exhaustive testing.  These were further refined and the compact design that is the Mini-Lathe Dream
Cutter ultimately emerged. The Mini-Lathe Dream Cutter can perform most operations better than a
stock compound, and many others that are not even possible without complex, dedicated attachments

Many have discovered this site through a youtube video (“ManOverMetal”) of a radius cutter for an  8×12 lathe that featured a cam-lock pivot adjustment and standard toolholder.  This project was the inspirational launching point for a new approach that solves many problems inherit in earlier designs.

The Mini-Lathe Dream cutter is a replacement compound rest that features many advancements and innovations that permit many operations that have not been feasible including turning and parting a near perfect sphere in a single operation from a unprepared rod end.  Note the double adjustable radius pivoting design allows for unprecedented reach and flexibility.  We have several product lines in various stages of development for larger lathes. The mini-lathe version was undertaken first to prove the design concept feasibility with the most compact of equipment to facilitate follow on lines by scaling up the design for larger mass machines.

The production batch of Mini-Lathe Dream Cutter assemblies is being made in San Diego. They are CNC machined in CRS and SS.  The initial batch of assemblies will are hand fitted, tested and Q&A by Aug 1. Pricing and availability will be announced when product is acceptable to our standards and deemed shippable. For this reason we will defer pricing to until final costs have been tallied, as this being the first product launch I am dealing with too many unpredictable variables.

Thanks for your interest. We have invested a lot into Dream Cutter and realize customer satisfaction and is the key to success.  That takes strong product value and responsive customer service to achieve. With that spirit I welcome any questions, comments or suggestions.

Mini-Lathe Dream Cutter™

Compound Radial Multi-Tool

The Mini-Lathe Dream Cutter™ is a bolt-on accessory certain to revolutionize the mini-lathe market. Offering an unprecedented level of tool control in a compact package, the Dream Cutter’s design (patents pending) overcomes the limitations inherit in miniature machine tools.  The Dream Cutter extends the mini-lathe’s standard compound rest with two additional axes of controlled tool articulation combined with a fully adjustable quick release tool holder.  The Dream Cutter performs traditional lathe operations better, and accomplishes other tasks previously considered impracticable on mini-lathe equipment. Key capabilities and features include:

The Dream Cutter’s multi-functional approach is ambitious, however diligent engineering and manufacturing craftsmanship has resulted a highly refined and capable product.  The convergence of these functions also permits the Dream Cutter to perform Compound Radial Cutting ™  Compound Radial Cutting (patents pending) is a new lathe turning technique where the cutting tool is swept simultaneously or independently in sub-ordinate radii arcs where the tangent to the work axis is controlled by an over-arching primary radius arc.  Compound Radial Cutting is applied with the Dream Cutter to maintain radial tool path continuity, improve material removal rates, and reduce surface finish waviness.  Recognizing rigidity is vital to the tool’s effectiveness; structural integrity was an unwavering focus in the Mini-Lathe Dream Cutter’s development. The result of this focus is a tool which maintains the highest possible degree of precision while demonstrating the full range of its capabilities.

The Mini-Lathe Dream Cutter is installed using a mounting plate which fastens to the cross slide saddle in place of a compound rest.  Approximately ½” in height, the mounted body of the Mini-Lathe Dream Cutter is low enough to pass under a 3” lathe chuck. The Dream Cutter’s controls can be configured in either in direction on the rail re-orient the tool post mount.  The multiple configurations of the Mini-Lathe Dream Cutter allow for up to a 3” diameter sphere to be cut and perform tapers at any angles in either direction.  The Mini-Lathe Dream Cutter includes a feature-packed tool holder that’s fully adjustable to accommodate a wide variety of tools. 

Hobbyist, craftsman, artisan and industrial machinists will appreciate all the ways in which the Mini-Lathe Dream Cutter™ breaches barriers to creativity.  Operators of small bench top lathes such at those offered by Proxxon® , Schaublin® , Seig® , Sherline® , Taig® , Wabeco® and others will discover the combined the features of the Mini-Lathe Dream Cutter can speed most cutting operations, allowing for complex turned pieces to be created with minimal interruption to cutting operations.  

Availability and pricing to be announced August 2010.