Manual and CNC Machining Projects
Precision Manufacturing and Component Fabrication
Project overview
This collection documents hands-on manual and CNC machining projects focused on producing precision mechanical components from CAD models and engineering drawings. The work emphasizes machining fundamentals, design-for-manufacturing, and iterative improvement through physical fabrication. Projects span manual mill and lathe operations, CNC milling and turning, and supporting welding work, with an emphasis on dimensional accuracy, surface finish, and functional integration.
Project: Machined Screwdriver
Objective
Design and fabricate a functional hand tool emphasizing concentricity, ergonomics, and surface finish.
Manufacturing process
Manual lathe operations for shaft and handle geometry
CNC mill operations for feature machining and finishing
Key engineering considerations
Concentricity between handle and shaft
Surface finish for grip and usability
Tooling and setup sequencing
Validation
Dimensional inspection and functional use testing
Media
Project: Pressure Distribution Block
Objective
Manufacture a precision block with controlled hole placement and internal flow paths.
Manufacturing process
Manual milling and drilling operations
Layout and datum referencing for accurate feature placement
Key engineering considerations
Hole location tolerance and perpendicularity
Flatness and sealing surfaces
Machining order to maintain accuracy
Tapped holes for pressure hose barbs
Validation
Dimensional inspection and fit verification
Media
Project: Threaded Components
Objective
Produce threaded parts to specification for mechanical integration.
Manufacturing process
Manual lathe threading operations
CNC lathe exposure on Haas equipment
Key engineering considerations
Thread form accuracy and pitch control
Tool selection and cutting parameters
Fit with mating components
Validation
Thread gauges and functional fit testing
Media
Project: Custom Washers and Inserts
Objective
Fabricate tolerance-controlled washers and inserts for assembly applications.
Manufacturing process
Manual lathe and mill operations
CNC milling where repeatability was required
Key engineering considerations
Thickness tolerance and parallelism
Inner and outer diameter control
Batch consistency
Validation
Assembly fit checks and dimensional inspection
Manufacturing tools and capabilities
Manual mill and lathe (certified)
CNC milling on Haas Mini Mill
CNC lathe experience on Haas equipment
Welding for fixtures, repairs, and assemblies
Engineering practices
GD&T and dimensional tolerancing
Design for manufacturability
Process planning and setup sequencing
Iterative improvement based on physical feedback