Manufacturing Process
The components of the welding system were manufactured using standard machining and custom tooling. The copper tips were cut to length, sanded to shape using a jig, and bent into final geometry with a custom mold. The tip block was CNC machined with precision holes for press-fit insertion, and additional features were milled to mount it to the actuator. The final assembly ensures alignment, repeatability, and modularity.
Press fit.mp4Figure 9. Press-Fitting Tips into Block
Simultaneously inserting all five copper tips into machined press-fit holes to complete electrode.
Sanding tips.movFigure 10. Tip Sanding Process
Spinning copper rod against sanding belt using custom jig to achieve precise length and taper.
Cutting tips to length.mp4Figure 14. Tip Cutting Setup
Using manual metal cutter to cut tips to size after sanding
Puzzle piece.movFigure 15. Puzzle Piece Milling
Cutting semicircular profile on the mold face using an end mill to guide precise tip bending.
Side bend.MOVFigure 16. Side Bend Demonstration
Manually bending each tip sideways to 30° using guide tube and mold slot to ensure precision.
Downward bend.MOVFigure 17. Mold Closure Setup
Closing vise jaws around mold halves to hold tips in position for uniform downward bending.
Figure 18. Final Bent Tip Array
Top view showing all five tips after bending, aligned with consistent angles and spacing.
Figure 19. Mold with Bent Tips
Final electrode positioned in PLA mold, illustrating successful simultaneous downward bending.
Figure 20. Side View of Single Bent Tip
Close-up of one bent copper tip showing smooth curvature and final shape.
