Initial Experience
For my first time using a milling machine, I struggled a lot with the design and use of the machine. This project aimed to create a practical bookend that could hold an array of books. While the project seemed straightforward initially, navigating the software and limitations required more adaptation than I anticipated. Although I encountered challenges with designing in Easel, I aimed to achieve a well-functioning design that met both the aesthetic and functional goals of the project.
Design Process
I began by designing an interlocking piece to connect the bookends. Once I designed the interlocking component, I added a bronco stand that would lean against the bookend, giving it an aesthetic look based on the SCU mascot. After finalizing the design, I transferred the file to the Easel Pro Version at the Maker Lab for print preparation. I spent about 15 minutes setting up the settings and setting the slab on the Carvey machine, focusing on achieving the right layer height, thickness, and supports. This step was crucial for ensuring the mill adhered to correctly fit the design specifications.
Milling and Assembly
With everything prepared, I proceeded with the cutting process, which took a little over an hour. Unfortunately, the results were not exactly as I had envisioned. Firstly, the Bronco stand did not fit perfectly into the carved-out hole, leaving a noticeable gap, as seen in Figure 2. To address this, I used wood glue to fill the gap and secure the stand in place. Secondly, the interlocking piece was miscalculated. During the design phase in Easel, I assumed that increasing the size of the insert piece would ensure a better fit.
Figure 1: Back of the Bookend, Interlocking piece
However, it turned out to be too large, resulting in a loose connection, as seen in Figure 1. To resolve this, I applied a significant amount of wood glue to tighten and secure the interlocking joint.
Reflection and Learning Outcomes
This project taught me the nuances of tolerances and their importance when using a milling machine. I learned the importance of precision in software design and material setup. Although Easel presented challenges, it reinforced my understanding of the need for careful planning when transitioning from digital designs to physical products. Working on this project also gave me hands-on experience with problem-solving and adapting designs to solve unforeseen issues.
Figure 2: Insert Bronco Piece Gap
Total Time Log:
45 minutes creating the initial design in Easel
1 hour refining the design and adding details
30 minutes (for both) setting up the Carvey machine
1 hour 30 minutes milling
45 minutes troubleshooting and assembly
TOTAL: 4 hours 30 minutes
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