Panel Pro 6126

View a video of one of a Panel Pro model 4824 cutting instrument panels provided by our good friends at D’Marco Areo SAS

How to order.  Please contact us via our contact page or phone.  We will prepare a quote to include accessories and shipping to your location.  Upon your acceptance of the quote you will be added to our build schedule. They are shipped in order of order date.  

click picture for Hi resolution image

Another video producing back lighted panels.

What is a Panel Pro™?

The Panel Pro™ model 6126 is a computer controlled router optimized for aluminum sheet metal 1/8″ thick. It is at home in avionics shops, Completion centers, or anywhere complex routing is required.  It has an x axis (width) travel of 59 inches, y axis (height) travel of 25 inches, and a z axis (up and down) travel of 3.125 inches. With multiple passes, aluminum as thick as 1/2″ can be cut.  All 3 axis are computer driven with heavy duty NEMA size 23 stepper motors. Back to Top

How fast is it?

It takes about one hour and twenty minutes to cut all of the cutouts of a complete 4 foot wide King Air 350 panel.  The cutting speed is dependent on the material being cut and the desired finish, but an average cutting speed is around 20 inches per minute using 1/8″ 2024 t3. Back to Top

How accurate is it…?

Move resolution is .0001968 of an inch (about two ten thousands of an inch).  Each Panel Pro 6126 is laser tested and employs a table that corrects lead screw errors.  Using a rough and fine cut, hole diameters can be held to better than .002″ with a very light burr and good surface finish.   The 6126 has home switches for a repeatable absolute zero in X,Y and Z.  It has hard stops on the X axis so the X to Y square can be checked and reset easily.  Back to Top

Square corners…?

The minimum corner radius is dependent on the end mill used.  Most cuts are made with a 1/8 inch end mill, therefore the minimum corner radius is .0625 inches. Cutouts that require a very tight fit along with sharp corners may require minor corner touchup with a file. Typically a cutout like a .700 inch square annunciator can be opened up just a few thousands to minimize or eliminate any filing.  The cutter may be changed to a smaller diameter (required to make #3 rivet holes) but rarely needed for general panel work.  Back to Top

Can I countersink…?

The Panel Pro 5126 can perform specialized operations such as edge chamfers and insets.   Countersinking on the Panel Pro is not recommended.

3 axis operations.

All 3 axis are motor controlled.  The supplied AvCAM software automatically controls the Z axis which ramps down into a cut that is automatically calculated.  When it is done cutting a closed figure, it raises up to travel at rapid rate to the next cutting location.  Multiple depth passes are supported.  If the user so desires, AvCAM will respect z coordinates in the DXF file.  Normally the Z axis is left at zero and AvCAM will cut at a cut depth entered by the user.

What can I do with it … ?

While Instrument panels are its specialty, the Panel Pro™ is equally at home fabricating brackets, doublers, switch and connector plates, flat pattern mounting trays, and even honeycomb material.   Optional engraving hardware is available.  You can use the Panel Pro™to digitize panels with the measure pro accessory.     Back to Top

What materials will it cut…?

  • Aluminum sheet metal is the primary target material.
  • Plastics such as Plexiglas cut very readily when a single flute end mill is used.
  • Honeycomb.
  • Carbon fiber.
  • 4130 steel.
  • Wood is not recommended.

Back to Top

Computer requirements

The Panel Pro™ requires a Personal computer with a Windows 10 operating system.   A USB port is required to communicate with the SC3 Controller.  A lap top will technically run the Panel Pro, but a keyboard with a numeric keypad and a mouse with a wheel are mandatory.  A lap top should not be considered for the primary work station where drawings are made due to limited screen space.    Back to Top

Maintenance requirements

The only routine maintenance is to clean the linear bearing ways and lubricate them with a light oil spray such as WD40.  Clean the chips out of the drain pan.  The linear bearings have grease fittings and should be greased once a month.  The Milwaukee 3 1/2  router has a brush type motor. With heavy use, the brushes will wear out in a year or so. The brushes are field replaceable.  In 10 years or so, it is a good idea to give the machine a good detailed inspection. Routine operating supplies are available from us and local vendors.    Back to Top

Shop Space


The basic machine takes up a 4 foot by 6 foot rectangle. It is desirable to have access around the back of the unit, and a table for the computer. If an individual room is contemplated, the absolute minimum size would be 8 x 8.   The area should be well ventilated and preferably air conditioned.   With the legs removed, two people can carry the Panel Pro™ through a normal passage door.  The computer screen, keyboard and mouse should set close to the Panel Pro at a right angle to the machine so the operators can have their right hand on the keyboard, and their left hand on the middle of the machine. The machine weighs about 300 pounds fully set up and can be installed on a non reinforced floor.  Back to Top

Shop utility requirements

The shop should provide 110Vac 60hz power on a 20 amp circuit. It is desirable to have a source of running water nearby to flush chips from finished parts and hands.  The system will function 0n 50Hz, but will require an inexpensive transformer to convert 220-250VAC to 110-115VAC  Back to Top

What is the process..?

  1. Make a drawing of each instrument or cutout that is to be included in the finished panel. Once an instrument has been drawn, it is stored for re-use as required.  AvCAM has utilities to rapidly generate instrument cutout cad files when given dimensions.  In most cases a cutout from the supplied drawing library will be inserted into the panel drawing.
  2. Make a drawing of the instrument panel.  Again store this for future re-use.  The beauty of this system is that once a cutout or panel is drawn, the work is done.  Panel Pro™ buyers receive our current library of cutouts and panels (serial number specific) that will save countless hours of research and drawing.  The cutout files supplied have close tolerances unlike many manufactures cutout drawings.
  3. Simply insert the panel drawing and the desired instruments in a new file, save them as a dxf file and cut.  In many cases a panel drawing with instruments already exists.  Then it simply is a matter of removing the old instruments and inserting the new ones.  Once a drawing exists as a dxf file,  it can be previewed or routed with AvCAM and the Panel Pro.     Back to Top

CAD software

We supply a 2d Computer aided drawing program with the machine.  Currently we are Shipping QCAD.   We are aware that many shops already use CAD.  In many cases these may be satisfactory.  Call us for recommendations.

Any program that saves drawing entities as a spline or exploded spline will not work except in some rare instances.  Examples are Corel Draw, and Adobe Illustrator.  We are happy to evaluate drawings produced by your CAD and will comment on their suitability.  Programs such as Adobe Illustrator, Corel Draw, Fusion 360 and others are not suitable.

AvCAM machine operating software

AvCAM version 19.xxx is a Windows application that:

    • Reads dxf files produced by a CAD program to cut entities on selected layers.
    • Automatically applies tool paths for the end mill size entered by the user.
    • re-organizes the dxf file lines and arcs into polylines that proceed ccw for inside cuts and cw for outside cuts placed on the layer called “outside”.
    • Simulates the cut, and estimates the time to cut with current settings.
    • provides a digital readout of machine position as well as a graphical representation of where the machine is on a cut.
    • Provides numerous software tools to aid in alignment of existing panels and setting origin points.
    • Generates common instrument dxf files in seconds.
    • Incorporates interactive “jog” mode for manual control of router.  The jog mode employs not only rapid movement across the movement area with keypad keys, but fine movement in a selected axis in .01, .001, and .0002 increments.
    • Provides text engraving support.
    • Provides Laser engraving support.

  • Generates the indexer signals for the X,Y and Z axis.  Automatically turns spindle and coolant pump on and off.
  • can be operated in the cutting mode or measuring mode with the optional Measure Pro.
  • limits travel to machines travel limits when the normal homing commands have not been over ridden.
  • Download AvCAM help file  for a closer look how AvCAM operates, Save it to your desktop, then open it.   Back to Top
  • Provides Operating modes for Automatic tool path, Measuring, Engraving, and laser.

SC3 stepper motor controller

    • converts the commands created by AvCAM  into the micro steps  that drive the X, Y, and Z stepper motors.
    • controls the spindle motor power with solid state relays.
    • controls the coolant pump power simultaneous with the spindle power.
    • Controls optional LZ1 laser engraver.
  • Provides  a manual  switch to inhibit spindle rotation.
  • Provides hard wired pause switch
  • Provides key operated laser power supply
  • Provides emergency stop switch
  • Provides interlock circuit for customer implemented safety curtains.
  • Monitors home switches during home commands.
  • Reads the Measure Pro position sensor to measure existing panels.
  • Powered by 110vac.  Back to Top

Coolant system

Most of the heat of the cutting process is carried away with the chips.  Formula #78, a people / environment/machine/material safe water soluble lubricant is pumped to the spindle where it cools and lubricates the end mill.   The chips created by milling are flushed away from the cut into the drain pan and filter.  This results in a clean workplace.  The coolant pump automatically runs any time the spindle is running.   Back to Top

Material mounting

The Panel Pro™ uses a simple system of movable rails to clamp the material being cut with C clamps.  When an instrument is cut out, the core drops free of the cutter into the drain pan. Panels with rolled edges such as the King Air will utilize a spacer between the panel and the mount rail equal to the depth of the rolled edge. The depth of the drain pan can accommodate up to 9.5 inches of bracing on the back of the panel. Back to Top

Safety Features

  • The router and coolant pump are protected by circuit breakers and ground fault interrupters.
  • The controller has a emergency shut off switch.
  • The controller has a remote interlock circuit available for customer implementation of custom safety curtains.
  • The cutter has a mechanical splash guard that also keeps fingers clear.
  • There are warning labels for hearing and eye protection as well as pinch points.
  • When implemented, the LZ1 laser has multilevel safety that starts with a key lock circuit, software messages that require user response to inform that the laser is arming, and indicator lights showing when the laser is active.  In addition software interlocks prevent accidental laser firing. Back to Top

Training

You are welcome to travel to our facility to train for one day at no cost other than your own travel expenses.   This will cover all basic operations and will prepare the trainee to prepare the drawings, operate the Panel Pro and its accessories. Back to Top

Support

We are available by phone and email for questions and help.  There is no charge for support.  We welcome calls from new customers as well as purchasers of older Panel Pro machines.  We carry replacement parts and supplies for the 4824, 5624 and 5925 machines. Back to Top

How can my business justify the purchase of a Panel Pro?

The Aviation industry and Avionics in particular are hard pressed to find quality technicians.  These technicians are sometimes not available at any price.  As a result the technicians you have must maximize productivity.  Instrument panel planning and research must take place regardless of the panel manufacturing method.   One important difference using pre drawn instruments and panels, the layout can be confirmed without the aircraft present, allowing owner concurrence and early submittal of FAA approval paperwork.

It will take a skilled technician 24 hours to manually fabricate a typical pilot’s instrument panel.  It will take the Panel Pro™ 30 minutes to cut out the same panel.

There are other operations in the panel fabrication other than the actual cutting, so let’s be generous and say that the actual time for a technician to cut the panel without painting, etc. is 16hrs.  At a shop rate of $85/hr that is $1360 vs $57 for the Panel Pro.

Every panel that is cut with the Panel Pro will allow that technician about 15 hours to work on other portions of the installation rather than the panel

Stated yet another way, it will take only 13.6 panels to pay for the Panel Pro Back to Top

Will I need highly skilled people to operate the Panel Pro?

It is helpful to have a basic knowledge of computer aided drawing programs.  Once the drawing is created for the Panel Pro, it is a straight-forward task to cut the file.  The operator will need to at least have a basic knowledge of computer operation.  We can provide one day training at your facility for a Panel Pro™ Owner who purchase their machine new for direct expenses.  Subsequent training is available at a rate of $500 per day on site plus expenses.
Self study training materials are included with the Panel Pro.
Top

Why shouldn’t I just get a milling machine or CNC milling machine?

10 x 54 Milling machine:

  • weighs 3000 pounds
  • 38.5 x 17 travel
  • costs $8000
  • t-slot material mounting does not accommodate cutout slugs
  • No chip control
  • manual operation, many manual tool changes required to cut a panel.
  • impossible to cut complex curves

10 x 54 cnc same as above but:

  • costs $39500
  • automatic operation
  • requires additional expensive software.
  • uses difficult to program G-code.

Panel Pro:

    • Weighs 300 pounds.  Suitable for un-reinforced floors.
    • 61 x 26 travel accommodates most full instrument panels
    • costs $18995
    •  material mount and chip control optimized for sheet metal work.
    • The entire process from drawing to cutting is optimized for the way a small shop operates.
  • easy to use software included
  • extensive Aviation drawing library included.
  • World class support available by phone and email.

 Back to Top

Shipping Size and weight

  • The crate size is 73 x 48 x 24 inches
  • The USA domestic shipping weight is 455 pounds including normal options
  • The international shipping weight is 530 pounds including voltage converter and normal options.

 Back to Top

Price and delivery

The package Price is $19995 USD, which includes:

    • The Panel Pro™ 6126 machine tool.
    • SC3 controller.
    • Interconnect cables.
    • Variable / regulated speed  router with a collet adapter to use industry standard ER11 collets.  1/8, 3/16, and 1/4″ collets are provided.
    • AvCAM version 19 machine operation software
    • QCAD 2D computer aided drafting software
    • A copy of our extensive aircraft instrument panel and instrument drawing library.
    •  coolant system with 1 gallon coolant.
    • starter supply of high strength carbide end mills.
    • hand tools needed for operation.
    • A pen plotter adapter to draw out panels or parts in full size.
    • shipping weight in a sturdy plywood crate is 455 pounds, size 48x24x73 shipping class 92.5.
    • Each Panel Pro takes about 2 weeks to manufacture and each order is processed in the order received.  Call us for lead time.

All you need to provide is a computer with a 64 bit Windows 10 operating system.

Lap top computers are will operate the Panel Pro if they have a separate numeric keyboard and mouse with a mouse wheel.  However, the limited screen area of most lap tops is far from optimal for drawing.

Back to Top