Milling About
This project aims to expose us to new facets of engineering and design; intertwining many processes, programs, machines, and skills together. This project uses the Fusion 360 and Corel Draw designing, laser cutting, and collaborative engineering knowledge I have already attained in pair with new and complex workspaces, software, and machines. This includes switching between Fusion 360's design and manufacturing workspaces, learning to use and navigate Bantam Software, and learning the basics of Othermill Wax milling components, processes, and design.
New Machines I Used
Dog Tag
First Dog Tag Design
The design pictured is the blaze (white facial markings) on my horse, Dominga. I choose to do this as whenever I see Dominga's blaze from afar, I can always recognize her and automatically feel happier. Thus, I chose to keep some happiness "on-the-go" with me on my keychain. The letters, MMXXI, are the roman numerals for 2021, the year I got Dominga. I chose to use roman numerals over traditional numbers as one of my most challenging but rewarding classes is Latin. The hurdles I have overcome in Latin class always make me feel proud. I created this design by sketching a picture of Dominga's blaze in the app Notability.
Final Design
To create my final dog tag design, I first uploaded a picture of my notability sketch into my Google Drive. Next, I downloaded the image into the remove.bg website to remove the background of the image. I then saved the new file and then uploaded it into Corel Draw.
From there, I right-clicked the image and selected 'bitmap tracing' from the drop-down menu. Under the setting selection, I selected the trace type as outline, the type of image as line art, the smoothing value as 21, and the corner smoothness as 66.
Next, I measured my physical dog tag with calipers and changed the document size to its dimensions, a width of 2.201" and a height of 1.505". I then imported the provided file of the dog tag's outline and positioned my bitmap in the center of the outline, ensuring it did not overlap with the hole on the dog tag where the chain would be threaded through. After positioning, I got rid of the outline and saved the file to my Google Drive.
Dog Tag in Bantam Software
Othermill Desktop Milling Machine Workflow
Open the Bantam Software on an OtherMill Desktop
Turn on the OtherMill Milling machine by flipping the switch on the back right of the machine
Import gcode file
Take all the plastic, acrylic sides of the milling machine off
Place a small piece of padding under the bit in case it falls while you are changing it
Get the two wrenches and place one in each hand
Set them on the bolt and turn your left hand to the right and your right hand to the left to loosen the bolt
Remove the current bit
Stick the end of the 80 degree Metal Engraving Bit in
Tighten the bolt with your fingers enough to where the bit will hold in place but is not fully secure
Use the wrenches again and turn your right hand to the right and left hand to the left to tighten the bolt
Put the sides of the machine back on
Select the Metal Engraving Bit (80 degree) under the “change” tab
Click "locate tool"
Apply the neto tape to the back of your tag to prevent it from moving and cut the excess tape around the tag
Get calipers and click the on button, select units mm, and zero the calipers
Measure the width (X), height (Y), and thickness (Z) of the dog tag with the neto tape on
Click "loading" in the Bantam Software to bring the machine bed forward for more easy tag placement
Remove the front panel from the machine
Place the piece in the front left corner of the milling bed with the sticky side down
Replace the front panel
Under the size tab in the software select "custom size" and input the measured sizes: width of 49.5mm, height of 28mm, and thickness of 1mm.
Select the left bracket alignment
Under the sides tab click "cutoff" to make the machine engrave
Input an engraving depth of 0.15mm
Change the placement to 15 in the x direction and 6 in the y direction
Select the "Metal Engraving Bit 80 degree" under the milling tools tab
Click "mill all visible" and "ok" to start the machine's milling
Once it has finished, click the "loading" button and take all the panels off the machine
Use the scraping tools to pry the tape and remove the dog tag from the bed
Once it is out, ensure you do not touch the design with your hands to prevent getting metal pieces on your hands
Take a paper towel and sanitation spray to wipe the small metal pieces off
Video of the Dog Tag Being Engraved
IMG_3445.MOVThe Final Dog Tag
While milling my dog tag, I found the Bantam Software confusing to use while using the desktop milling machine. To resolve this, I asked my group partner, Julian, and teacher, Mrs. Morrow, for help.
Chocolate Wax Mold
Rough Sketch of Mold
My Fusion 360 Chocolate Mold
For my Fusion 360 chocolate mold design, I made a star-shaped mold as it will be applicable to many different holidays and occasions. Although the following process of making the wax mold will be done with a partner, I decided to make my own individual design so I could gain the experience and practice with the different Fusion 360 tools and workspaces.
Fusion 360 Tool Path Simulation
To shift between the star in the Design workspace to the Manufacturing workspace, I selected "Design" in the upper left corner and clicked "Manufacturing." I then clicked pocket clearning under the 3D tab to select where and how I wanted the milling machine to mill the wax. Next, I added a toolpath by selecting the milling machine, importing a special tools library, and selecting the 1/8" Metal Engraving Bit (80 degree). Next, I saved this file as a gcode and imported it into the enjproj folder so I could acess it on the OtherMill Desktops.
Screen Recording 2023-03-10 at 7.39.03 PM.movIMG_3467.MOVVideo of Wax Milling
The software for this machine is different from the smaller, Othermill Milling Machine used for the dog tag from earlier as it is larger and the software requires more instructions for your desired results.
Wax Before Milling
Wax After Milling
Chocolate Box
Corel Draw Chocolate Box Design
To design my chocolate box in Corel Draw, I started by creating squares and rectangles of what I assumed the box should look like. From there, I adjusted the dimensions to fit four to six chocolates. Then, I started to color the lines and subsequently had to use lines to trace some of the rectangles to create different colors in the rectangles. Next, I imported a vector image of a chocolate bar and placed it on the top of the box. The difference in color is important so that, when on the Epilog Laser Cutter, I could group different cuts by color. I included flaps in the design so that the box could be glued together without any glue being exposed to the chocolate and so it would stay closed and sealed.
Trial-Run Box
IMG_3478.MOVThe Final Product
IMG_9271.MOVProblems Encountered
The majority of roadbumps I encountered throughout this project I resolved with quick conversations with my classmates and the engineering teachers.
While milling my wax mold, my partner and I accidentally went over the side of the wax. To resolve this, we discussed making the star design smaller, slightly changing the position of the star, or getting a wider wax piece.