Router Vs Spindle Which Is Better?

In past years with more availability and affordability in cnc applications the question of router vs spindle has been debated. We need to look at what each offers in order to understand why one is better than the other.

If you are looking at cnc router kits to build with, in the end I am sure the answer will be clear that a spindle is far better than a router.

Many would consider a router to be a basic starting tool for woodworking. It was a natural adaptation by need for its use in cnc applications.

In the early 2000’s using a wood router was almost the status quo. Spindles were something which the average woodworker could not afford. Those that were available at lower cost simply were not worth the money. Times have changed in what can be had in terms of cost and longevity of service.

Router In Cnc Use

There was a time when the average router was significantly cheaper than a spindle. This is not so much the case any longer. For me the greater issue comes back to what you get for your money. The wood router today is not as well made as those in history.

Those older hand tools from the 70’s and 1980’s in general are consistently better built. But they are hard to find. I am lucky in that I have a few and they are worth keeping and rebuilding if needed. Maybe it is just the nostalgia but there is no doubt in my mind the construction is quite different.

When it comes to cnc use there are issues that I find. The main problem behind using a router is that it is a brushed motor. When used for this purpose especially in wood art the run time I personally would need no doubt will burn it out quickly. I have jobs that can run 8 to 10 hours on my mill non stop.

Much will depend on how often you need your cnc. If you run longer jobs and it sees daily use then you may want to consider other options. On the other hand if your run time is much lower then there are advantages in a simple setup.

If your mill gets periodic use then you can save the added cost of upgrading to a spindle. Most of us woodworkers have a router on hand laying around the shop. It can be mounted onto the cnc when needed and then removed. Albeit many cnc mounts require modifications to the router for mounting so switching the router for other uses can become a royal pain.

Nevertheless if one is laying around the shop and generally not in use it is an easy choice. Yet another question comes to mind. How accurate do your cuts need to be? I have consistently found that a router cannot match the accuracy of a spindle.

The locking nut for routers is not designed to give the same level of accuracy. Additionally with time, wear and tear, these parts are not as easy to change. You also are locked into the size bit which the router requires for use. This may be limiting in some applications.

Last but not least is noise. Routers are incredibly loud. Osha considers anything under 80db to be safe levels. The router can easily reach over 100db consistently. The same can be said for high speed spindles yet much can be said for the pitch in the sound difference and speed impacts decibel levels. A router on the other hand is either on or off.

Cnc Spindle Applications

Among the advantages of a cnc spindle the matter of it not being a brush driven motor is critical. Technology and manufacturing in China has vastly improved over the years in these terms. This helps us for China is where the most affordable options come from.

In terms of run time I have used mine for years while it saw operation anywhere between 4 to 8 hours a day. As long as you set your vfd properly and keep it running within parameters it is designed for it should serve you well.

The only issue with these is that there can at times still be problems with consistency across manufacturing. You will find that some are better than others of the same model.

Another major advantage is that a spindle uses a collet and collet nut to lock the bit into place. This offers two differences. The first being that you can use different size bits. Simply swap out to the needed collet size for the bit and you are ready to go.

The second difference is accuracy. Know that you will get what you pay for so I would avoid Amazon shopping for these. Yet when properly made they can offer great accuracy which cannot be had any other way. The design is made in such a way that two wrenches are all you need to swap out these collets with ease and minimal down time.

In terms of noise levels they are very quiet when just the motor is running. You would not need any hearing protection until it begins to cut the wood. The majority of its noise comes from the cutting process where the bit meets wood. In cutting it is advised that one still wears hearing protection.

In terms of costs these spindles now rival that of routers but there are hidden expenses. A better made router will run you close to the same cost of these Chinese spindles. With this said the cnc community may have their misgivings yet they clearly outlast the brushed motor of a router. That cannot be ignored.

A downside to using a spindle is found in additional hardware that is needed which a router does not require. You will need a vfd with power supply. So there is hidden costs in that regard. Additionally you will need to integrate the vfd into your cnc controller. Despite this additional cost and setup there are major advantages.

You gain the ability to control the speed of cutting by doing this. A router is either on or off. All that you can control with a router is the feed rate.

By using a spindle you gain more control over your cutting which in turn will yield far better results to your projects. In reality you do need to control both speed and feed rates with cnc applications.

Safety is also something you need to consider. In the event that you need to use an emergency cut off you need to look at how you engineer this part of your system. Too many that use a router do so without it having access to the emergency cut off. If the controller shuts down but the router is still running this is not good.

In terms of using a spindle it is already integrated into the system controller. Once a shut off happens the spindle will power down with the rest of the system by design. There is no need to worry about engineering an additional cut off or detrimentally shut down power to the entire system.

For these reasons it is clear that the benefits of a spindle far outweigh any additional costs from a vfd and power supply. You gain more performance in terms of accuracy and longevity. Additionally you gain safety with its integration. What it offers is more than you gain in trying to save money by using a router.

Air Cooled Spindles For Cnc

In recent years air cooled spindles came into the market and caught on as the in thing. I have tried one. In the end I did not like it. The sales pitch is that you no longer need to worry about water cooling for the internal fan will supply the cooling which is needed. There are some issues with this idea.

To begin with convection by air can never cool as quickly as conduction with flowing water through the system. The spindle will run far warmer than many may desire and will depend upon the air temperature within the room. For garage shops in the winter this may be okay, but the summer presents a challenge.

The problem compounds from the fan itself. When cutting a cnc will produce a lot of wood dust. Over time this fan is blowing the dust into the spindle housing. In turn this will reduce efficiency without you properly maintaining and cleaning.

An additional drawback that I found was that the spindle also runs louder than a water cooled system. In the end these combined drawbacks caused me to abandon the idea of air cooled spindles. I wanted to have more control with fewer variables.

Water Cooled Spindles For Cnc

A water cooled spindle is not difficult to set up. A 5 gallon bucket of water can act as your reservoir and a cheap pond pump can push the water through the lines. You simply hook up the lines to the spindle going in and back out to the reservoir. This system offers many advantages over air cooling.

Due to the water passing through the spindle it cools by conduction and is more efficient. Additionally as the water travels out of the spindle the warmer water is cooled as it passes through to the reservoir. Once there it continues to cool until it is recycled back to the spindle.

Over enough run time the water will warm up but should never allow the spindle to become too warm. Its temperature should always remain well below its maximum operating temperature.

If you work in a garage in the summer then add some ice to the reservoir for additional cooling. It is far easier to control than an air cooled system.

Another benefit is that the chamber the water passes through is a closed system. You do not need to worry about dust or debris getting into the housing and impacting efficiency. Once the system is set up and running it will continue to do so pretty much maintenance free.

Many people use additives to prevent corrosion. Starting with pure distilled water is a bonus. Yet among the common additives used antifreeze is a favorite with many. In this way the internal housing of the spindle will last far longer than simply using tap water.

Once someone sees that it is not a complicated system and how it offers more in temperature control it easily wins over air cooling. This will not stop some like me who had to experiment with the idea of using air.

The Best Choice Among The Options

For me it is clear that the best choice among the options is the water cooled cnc spindle. If you are setting up your cnc for the first time I know corners can get cut to reduce costs. At times a lack of experience or knowledge in setting up these systems can seem challenging.

If you are building your first mill I would not consider this area a place to cut corners on. It is the tip of the spear as so to speak in what will determine overall performance and outcome to your projects. It will carry the heaviest workload where bit meets wood with all your cnc cutting.

If you are still using a router application it is well worth considering the upgrade. Even if it is of the cheaper variety spindle it still will be worth the effort.

Variety Of Spindles Made Globally

Generally speaking a German or Italian made spindle is among the best in the market. Yet these can be quite expensive. Those who acquire them often look for used spindles but this too can carry some questions in terms of how they were used in the past.

There are more options which exist now within the Chinese market than before. Some manufacturers focus on quality to offer a hobbyist or small professional a bridge between the two worlds. If you are looking to focus on getting the best you can and money is no object I would look to European made.

If budgets are a concern as it typically is for most of us then it is worth the time to do research into Asian brands.