Making Things
Designing in the CAD/CAM tools I was helping build: Fusion 360 models, generative design, and parts fabricated at Autodesk's Pier 9, from composite prints to CNC-cut handplanes.
I enjoy making things, and making things better. At Autodesk I designed software for engineers and manufacturers, and these side projects were how I used that software the way our customers did: modeled in Fusion 360, then printed, milled, or cut in the workshops at Pier 9.
Using the tools end to end, from CAD model to toolpath to finished part, taught me more about where they broke down than any spec did.
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 machine this from metal.
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.
Coffee Grinder Hack
The Hario Skerton is a good hand grinder for the price, but develops a wobble over time as the metal shaft wears against a plastic part at a single point of contact. Ultimately this leads to an uneven grind.
I designed this simple pair of parts to hug the shaft at a second, lower point of contact. This prevents the assembly from wobbling, reducing wear and keeping the grind size consistent.
Download it on Thingiverse, and check out suneboe’s remix.
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 experimented with custom Kevlar/nylon composite prints, which are very strong and light. I also had designs to machine from wood or metal.
CNC Projects
After completing the beginner’s CNC course at Autodesk’s Pier 9, these were some of my starter projects.
Handplanes
A bodysurfing handplane is a small supportive device worn on your hand. Depending on its size and shape, it can make it easier to get barreled, help you hold position on the wave face, and add speed in the water.
This handplane was cut out on a ShopBot. From there, I used orbital and belt sanders to refine the shape. It needed more iterations.
Custom Chocolates
For a unique gift, I machined a positive of my design from wax on the Othermill, and then made a food-safe silicone mold negative from that to make custom chocolates.
This gift was a hit on all levels!
Generative Design for Additive Manufacturing
I am fascinated by the potential of generative design to enable a new era of design and manufacturing. It was still early, but this is a great example of people working with computers to create efficient, novel designs.
To get familiar with the tools, I explored 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.
