CNC Parts

Machined Electronics Enclosures

I am currently working on several projects that integrate machining with electronics. The first project is a LED control PCB that I designed in Fusion 360. I machined the housing using a full 5-axis simultaneous process on a HAAS TR160 trunnion table. This 5-axis toolpath allowed me to achieve a smooth 8-degree wall taper on all sides. I am also developing a fully CNC machined computer enclosure with a custom power button with a fully addressable LED array.

Eccentric Fixture for Bottle Bosses

Every cyclist needs to carry water on their bike! Water bottle holders usually attach to a bicycle frame using threaded bottle bosses that are welded or brazed onto the frame. I developed a modular fixture system to machine steel bottle bosses in batches of 16. During the first and second machining operations, the bosses are held by eccentric screws and clamps I machined out of steel. I also added backside screws to the second op fixture, which serve as a mandrel to prevent the thin threaded body from deforming. Total production output? Around 60 parts an hour!

Bicycle Components

Every year, the Bike Builders club builds a fleet of small “pixie” bikes. This project is an approachable way for new members to develop the fundamental skillset to build a bike. As the club’s manufacturing lead, I created all of the welding fixtures for the bikes and machined a variety of prototype components. Shown on the left is a square taper crankset, stem, and freewheel hub with steel loose ball cups.

First Op

Chainring roughed from 1/2” thick plate

Chainring After OP1

The chainring is shown here after OP1. Some stock remains on the periphery of the part.

Chainring 2nd/3rd Op Fixture Plate

This fixture plate locates and holds the chainring for the 2nd and 3rd op, which finishes the backside of the chainring.

2nd Operation

Here, the second operation has just been completed. The chainring is tightened via the 3 direct mount bolts and the outer tooth profile is finished.

3rd Op

Here, the inside of the chainring has just been finished. The chainring is held by button head flange screws through the outer teeth.

Finished Chainring

Narrow-wide Chainring

I designed and machined a few bicycle chainrings to develop my design skills and explore new fixture ideas. The chainring uses the 3-bolt SRAM mounting interface, which I validated using a go-no-go gauge I machined separately. I followed the Machinery Handbook guide to create a chainring with involute tooth profiles and created a fully parametric model. When I change the number of teeth, the model will automatically update. I used a fixture plate with threaded holes and locating features to machine the chainring backside in two operations.

5th Axis Bike Stem

I decided to make a bicycle stem as an introductory part on the TR160. Most of the stem is machined using 3+2 axis indexing, but several chamfers are machined using full simultaneous machine movement. The stem is a two-op part; most of the stem body is roughed/finished during the first op with the bar clamp cut off using a t-slot cutter. The second op roughs and finishes the rear cutouts and clamping holes on the stem body.

5th Axis Vise Riser

This is a simple 5th-axis part I made to use the 5th Axis D115 riser directly bolted to the TR160 platter. The riser allows for more part and tool holder clearance. OP’s 10 and 20 were completed in a Kurt vise mounted to the trunnion platter. Then, the final facing and mounting holes were done in OP30 with the riser mounted to the table. This project was a good way to validate the machine model and configuration I made in Fusion 360 for a VF2-SS and TR160.