TOPO MOUNTAIN — CNC Topography of Beirut, Lebanon
Project Overview
This project is a wooden CNC-milled topographic map of Beirut, Lebanon, created as part of my TOPO MOUNTAIN series. The goal was to transform geographic elevation data into a physical relief map using CNC machining, emphasizing both accuracy and craftsmanship.
The final piece was machined from wood and highlights the elevation contours and terrain variation of the Beirut region.
Photos / Videos
3D Printed Topo File Image
Topo Being Milled
https://github.com/user-attachments/assets/053faa4e-982c-4b83-8be0-fb1a95b9b857
Final Topo
Workflows (from Mr. Dubick)
CNC Topography Workflow
1. Terrain Generation (Terrain2STL)
- Navigate to https://jthatch.com/Terrain2STL/
-
Pan and center the map on the target location (Beirut, Lebanon) -
- Define the model area using the red selection box:
- Move, resize, and rotate the box as needed
-
Adjust terrain settings:
- Vertical Scale (Z-scale): Controls elevation exaggeration
- Water Drop: Lowers water bodies to emphasize coastlines
- Base Height: Adds a solid base beneath the terrain
- Generate and download the terrain model as an STL (.zip) file
2. Job Setup & STL Import (Aspire – CAD)
- Create a new Aspire file
- Set job type to Single-Sided
- Define stock dimensions (X, Y, Z) to match the material
- Set zero positions:
- Z-zero: Material surface (top)
- XY datum: Bottom-left
- Import the STL file and orient it:
- Orientation: Top
- Scale the model to fit the stock (Z height ≤ material thickness)
- Center the model in the workspace
- Position the model relative to the cutting plane to preserve relief and base thickness
3. Component Scaling & Positioning
- Adjust Shape Height to enhance vertical relief
- Set Base Height to raise the model closer to the top of the stock
- Center the component within the material
- Draw a rectangular boundary matching the final stock size
(Used for machining limits and profiling)
4. 3D Toolpath Creation (CAM)
Roughing Pass
- Tool: ⅛” flat end mill (ATC Tool #1)
- Strategy: Z-Level or Raster
- Boundary: Model boundary
- Leave a small machining allowance for finishing
Finishing Pass
- Tool: ⅛” ball nose (ATC Tool #6)
- Strategy: Raster or Offset
- Boundary: Model boundary
- Used to generate final surface detail
5. 2D Profile Toolpath
- Select the rectangular boundary
- Tool: ⅛” flat end mill
- Set cut depth to release the part from the stock
- Use climb cutting
- Tabs not required
6. Simulation & Export
- Preview all toolpaths together to verify accuracy and detail
- Check for missed areas or collisions
- Review machining time via Toolpath Summary
- Save the Aspire project file (.crv3d)
- Export combined toolpaths using the Carvera ATC post-processor
- Output a single CNC file that runs roughing, finishing, and profiling sequentially
PCB Toolpath & Milling Workflow
Key Notes
- 0.8 mm corn flat-end bit: Used to remove bulk material
- 0.2 mm × 30° engraving bit: Used to cut copper traces
- The Makera milling machine uses clamps (not adhesive), so tabs are required
- Toolpath usage:
- 2D Pocket: Copper traces
- 2D Contour: Board edge cuts
- 2D Drilling: Drill holes
PCB Toolpath Workflow (MakeraCAM)
- Open MakeraCAM
- Select 3-AXIS
- Edit stock settings:
- Material: PCB
- Length (X): 127 mm
- Width (Y): 101 mm
- Height (Z): 1.7 mm (FR4 thickness)
- Import all Gerber files using Import PCB
- Reposition Gerbers:
- Select all 2D layers
- Use Adjust Object → Transform → Move
- Set anchor point to Bottom Left
- Set X and Y to 6 mm
- Toggle visibility:
- Enable only F_Cu and Edge_cuts
- Create copper trace toolpath:
- Select 2D Path → 2D Pocket
- End depth: 0.05 mm
- Tools:
- 0.8 mm corn tool
- 0.2 mm × 30° engraving tool
- Material: PCB
- Click Calculate
- Drill holes (if applicable):
- Toggle visibility for drill files
- Select 2D Drilling
- Drill tip end depth: 1.7 mm
- Tool: 0.8 mm corn tool
- Click Calculate
- Edge cuts:
- Toggle visibility to show only Edge_cuts
- Select inner outline
- Choose 2D Contour
- End depth: 1.7 mm
- Tool: 0.8 mm corn tool
- Strategy: Outside
- Tabs: Custom, add ~3 staggered tabs
- Click Calculate
- Preview all toolpaths
- Export toolpaths:
- Select all toolpaths
- Rename file using:
LastName_FirstInitial_ProjectName_gcode.nc
PCB Milling on Carvera Controller
- Open Carvera Controller
- Connect to the correct COM port
- Switch to manual control interface and press Home
- Verify probe voltage is ≥ 3.6V
- Load the G-code file
- Preview toolpaths in file preview mode
- Select Config and Run
- Enable Auto Vacuum
- Enable Auto Leveling
- Click Run to begin milling
Issue Encountered: Incorrect Anchor Point
The Problem
During initial machining attempts, the project printed in the wrong physical location on the stock. After troubleshooting, I discovered that:
- The Aspire setup was referencing Anchor 2
- The CNC machine was zeroed expecting Anchor 1
- This mismatch caused the toolpaths to shift unexpectedly when running the job
As a result, the carving would start offset from the intended position, risking material waste and potential tool crashes.
The Solution
To resolve the issue:
- Returned to Vectric Aspire
- Verified the Job Setup → Origin / Anchor settings
- Reset the anchor to Anchor 1
- Re-exported all CNC toolpaths
- Re-zeroed the CNC machine to match Anchor 1 exactly
Once both the software and machine referenced the same anchor point, the toolpaths aligned perfectly, and the job ran as expected.
Files Included
3D Print File (stl)
Design File (ASPIRE)
CNC Toolpath
Lessons Learned
- Anchor consistency is critical: The software origin and machine zero must always match
- Always double-check:
- Job Setup
- Anchor point
- Material orientation
- A single incorrect reference point can invalidate an otherwise correct workflow
What I Would Do Differently
- Add a new and modified checklist before machining:
- Verify anchor
- Run toolpaths above material
- Label anchor points physically on the spoilboard
- Save multiple Aspire job versions with explicit anchor naming
Future Plans
- Expand the TOPO MOUNTAIN series to other cities
- Experiment with:
- Layered contour maps
- Resin infill for elevation contrast
- Larger stock sizes for higher resolution
- Explore automated scripts for heightmap preprocessing
Summary
This project reinforced the importance of precision not just in machining, but in setup discipline. Creating a CNC topographic map of Beirut was both technically challenging and personally meaningful. Resolving the anchor point issue improved my understanding of CNC coordinate systems and will directly inform all future CNC projects.
Project by: [Daniel Lokas]
Date: [12/16/2007]
Course / Context: [Senior Engineering]