Making Things

Time Period

2013-2018

Disciplines

3D modelling, CAD, CAM, CNC, Design, Engineering

I enjoy making things, and making things better. These are a handful of small 3D printing and CNC projects from my time at Autodesk (where I had access to amazing workshops at Pier 9). Almost everything digital was done with Fusion 360.

Hardware Experience

  • MakerBot
  • Ultimaker
  • Autodesk Ember
  • Mcor Iris 3D Paper Printer
  • Markforged Composite Printer
  • Stratasys Objet Connex500
  • ShopBot Router
  • Basic Wood Shop
  • Metabeam and Epilog laser cutters
  • Othermill desktop CNC


3D Printing Projects

Bike Light Mount

When carrying loads on a front rack, a handlebar light mount is virtually useless. After several prototypes, I settled on a design that could be easily mounted at the front of my rack with an M5 bolt. Eventually it would be cool to CNC this from metal.

Custom light mount
Custom light mount printed and installed
Custom light mount
No interference with basket or boxes mounted on the rack

Bike Bell Mount

A desired bell could not be mounted on a particular handlebar setup, so I designed and printed this extender to work with an existing mount.

Rendering of the selected bike bell mount
Rendering of the selected bike bell mount
Rendering of an alternative design
An alternative design

Coffee Grinder Hack

The Hario Skerton is a good hand grinder for the price, but develops a wobble over time due to the wear of the metal shaft against a plastic part at a single point of contact. Ultimately this leads to uneven coffee grind sizes.

I designed this simple pair of parts to hug the shaft at a second, lower point of contact. This prevents the assembly from wobbling, thus reducing wear and keeping the grind size consistent.

Download at Thingiverse or Github. Also check out suneboe’s remix Thingiverse

Partially assembled with parts in place (white)
Partially assembled with parts in place (white)
Fully assembled view from top
Fully assembled view from top
Design prototypes printed for testing and evaluation
Design prototypes printed for testing and evaluation; a key insight was moving to two pieces

Hand Strap Mounting System

How might we attach a safe, comfortable strap to a bodysurfing handplane so it doesn’t get lost in the surf? It should be adjustable, strong, buoyant, and resistant to salt water.

I am experimenting with custom kevlar/nylon composite prints. These are super strong and light. I also have designs I may machine from wood or metal in the future.

Design rendering of a composite strap mount (black)
Design rendering of a composite strap mount (black part)
Digital x-ray of the composite part
Digital x-ray of the composite part (fiber inlay in yellow)
Raw, unfinished protoype right off the printer
Raw, unfinished protoype right off the printer
Testing the prototype with a strap
Testing the prototype with a strap
Further design exploration
Further design exploration

CNC Projects

Having completed the beginners course on CNC at Autodesk’s Pier 9, here are some starter projects I have been working on.

Handplanes

A bodysurfing handplane is a small supportive device worn on your hand. Depending on size and shape it can be used to more easily get barreled, help with optimal position on the wave face, and/or get more speed in the water.

This handplane was cut out on a ShopBot. From there, I used a orbital and belt sanders to refine the shape. More iterations are needed.

First CNC project on the ShopBot
First CNC project on the ShopBot
First handplane prototype
First handplane prototype
First handplane completed
First handplane completed
Further design exploration
Further design exploration that would make use of the inset strap mounts above

Custom Chocolates

For a unique gift, I machined a positive of my design from wax on the Othermill, and then created a foodsafe silicone mold negative from that to make custom chocolates.

This gift was a hit on all levels!

The completed mold
The completed mold
Making chocolate with the molds
Making chocolate with the molds

Generative Design for Additive Manufacturing

I am fascinated by the potential of generative design to enable a new era of design and manufacturing. It’s still early, but this is a great example of humans working with computers to create efficient, novel designs.

To get familiar with the tools, I have been exploring generative designs for an Aeropress plunger (silver part). In this case, the algorithm was prevented from adding material in a sphere-shaped region right at the center of the standard plunger. You can see how it branched around while maintaining sufficient support for the material and loads.

Conceptual design for a generative aeropress plunger
Conceptual design for a generative aeropress plunger