RotoBoss Roller Rotary Setup

RotoBoss Roller Rotary Setup

Preface: This Article covers how to set up the rotary to get your steps right for a given tumbler and some best practices.

Best Practices and things to NOT do:

Below are suggestions to keep in mind when setting up and operating your Rotary to give yourself the best chance of success for today and for the future
1. Roller Rotary is installed with the motor to the Top Left
2. The machine knows when the Rotary is plugged in, you do not need to enable it from Lightburn
3. Rotary Steps and Roller Diameter are NOT saved with the Lightburn OR rd run file. You always have to set them up again.
4. In order to read or write Rotary Steps or Roller Diameter, you must be connected to the machine
5. Do not overtighten the tumbler in the Rotary, it can Slip. Tumblers from the same manufacturer can vary in length and roundness.
6. Use USER ORIGIN with the rotary. Not Current Position and Not Absolute coordinates
7. It is best to drive the larger diameter of a tumbler
8. Avoid driving on Threads of tumblers
9. Send, frame and Start all jobs from the machine (You can shift+send a rotary job but it is not ideal, you should frame before you run)
10. Full wraps and multi sided jobs add to the complexity and require more accuracy in setup
11. The larger you do your setup test square, strip etc the more accurate you will be
12. You want to place the rotary so that its is trammed with the laser head. Avoid using the edge of the honeycomb or machine as your guide
13. Save the Steps and roller Diameter, Cup type, Color etc of the tumbler with the Lightburn file using the Notes option
14. One pass...make it a good one. Do not try to do multiple passes or multiple layers. All graphics should be on 1 layer if possible
15. Line layers or Offset fill are not advised on a Rotary job
16. Test jog the rotary from the Controller Menu "U MOVE". Left and Right arrows will make the Rotary jog
17. Why do we mess with steps and roller diameter? To trick the rotary to spin the engraving surface the right amount. When we drive the tumbler from a smaller or larger area of the cup, the engraving area doesn't spin the right amount since it is a different diameter.
18. Circles will engrave to the correct diameter but since they are wrapped around a cup, they will appear as ovals. The Y direction of the circle needs to be stretched
19. Graphics are rotated to the left 90 degrees in Lightburn to engrave properly on the Tumbler
20. See the "Important Links" Section at the bottom of this article for more information


Here is a short tutorial on setting up The Thunder Laser USA improved roller rotary. 

4400 steps per rotation is a good baseline. Your roller wheel diameter will vary by model, be sure to measure and enter the proper value.

Reference Video:

Important Links:

    • Related Articles

    • TL-USA Unified RotoBoss Rotary Manual

    • Rotary Roller Diameter Calculation

      Preface The Roller Rotary differs from a chuck rotary since it provides rotation by surface contact.  A chuck rotary is locked into a degree of rotation of the chuck is a degree of rotation of the object and generally do no have adjustment for ...
    • Chuck Rotary Setup and Usage in Lightburn (Nova/Odin)

      Chuck Rotary Setup and Usage in Lightburn (Nova/Odin) The following article, supported videos and images will guide you to success with your Thunder Chuck Rotary.  NOTE* There are a few style Chuck rotary available through Thunder Laser, Please ...
    • X, Y and Z Honeycomb Axes will not move when Roller Rotary is plugged in and Rotary will not Spin

      This article describes the situation where when the Roller Rotary is plugged in, the X, Y and Z (Honeycomb) Axes will not move and the rotary will not spin. Other Articles of interest: Thunder 7 Pin XLR Rotary Port Rotary Axis no motion ...
    • RotoBoss JR Tensioner Relocation Modification

      THIS ARTICLE IS FOR THUNDER SPECIFIC ROTOBOSS JR DEVICES WITH ACRYLIC PLATES ONLY Is you tensioner mounted like this? If so it is at an extreme angle and under pressure. There is a modification for this version that needs to be done to your rotary ...