An on-site engraving machine

• Proposal:
  
  
  • This proposal explores the viability of the development of an on-site engraving machine, which engraves, or re-engraves, a monument or gravestone on-site - without the extraction of the monument. Computer Numeric Control (CNC) Routers, 3D scanning technology and software, and stone cutting hardware have advanced significantly in the last few years, so that we are very confident in our ability to develop the machine for $125,000.00.
    
    
  • The components of a complete system include (1) surveying the headstones to determine whether they should be cleaned, repaired, re-cut, or replaced (2) documenting existing lettering and condition of the headstone (3) estimating and verifying changes over time in the condition of headstones (4), as well as plans for both portable and fixed re-cutting machines. These components already exist in a form sufficiently close to the final requirements to justify the production of said machine.
    
    
• Construction Concept:
  
  
  • The cutting unit consists of a computer, software, scanning equipment, three-axis CNC router or milling machine, power supply, plus cutting heads and supplies. The weight of the router assembly rests on the ground, the 3-axis router frame is attached to the sides of the monument for stability and exact registration. The router can be mounted on a fixed or movable platform for convenience in set-up and moving from headstone to headstone.
    
    
  • The router will be operated through a computer, which will contain a scan or scans of the headstone in its database. The scanned information is used to generate the cutting instructions for the router. A variety of scanning options are available, including; digital cameras, laser scanners, modified desktop scanners. Special software converts the scan to cutting instructions.
    
    
  • The computer can be either an ordinary desktop PC with suitable adaptations for use out-doors, or a laptop. For most purposes, where the lettering is legible but worn, a good "business computer" or laptop will suffice. For more complex analyses and reconstructions, a more powerful computer and suite of software will be required. The computer relays cutting instructions to the CNC router, and monitors the progress and power used in cutting.
    
    
  • The database of photographs, 3D models for existing letters, 3D models for cutting instructions, close-up photos of problem areas, notes on wear rates and repairs, biographical notes related to the monument, and other relevant information allow a wide range of associated analyses. For instance, it would allow one to analyze each monument by style of font, distance between characters and whether the characters are stenciled or hand-carved. It could allow correlations between measures of hardness and surface roughness to be correlated with degree of wear and age of monument. Photos of monuments can be shared with older family members who are increasingly comfortable with "visiting" their loved-one's gravesite via the internet.
    
    
  • The cutting is done with a variety of tungsten carbide, super-abrasive or diamond bits. Depending on the depth and speed of cut, water spray cooling might be necessary to keep the grinding tool cool during the carving process. The control software should allow cold cutting of most marbles (cutting at shallow depths and slow speeds to reduce heat generation). The size and power of the router and the positioning motors sets limits on the cutting speed. One outcome of the design and testing will be showing the wide range of combinations which will accomplish the task to a given level of quality, at a reasonable cost.
    
    
  • All facets of the process will be documented and training materials prepared so that the equipment could be operated safely and productively. A cost-benefit analysis will be included to show where the approach is most valuable.