Langmuir MR-1 CNC Mill

Ball Bearing Maze

Objective - Construct a double-sided maze from a stock piece of 6061 aluminum.

Stock Dimensions 2 X 2 X 1in.

Maze Dimensions 1.875(1 7/8) X 1.875(1.7/8) X .78125(25/32)in.

Waste Stock Top .03125in. (1/32)

Waste Stock Sides .125in. (1/8)

Top Contour Depth . 8125in. (13/16)

Acrylic Pocket .125in. (1/8)

Maze Depth .125in. (1/8)

Mid Section .25in. (1/4)

Maze Depth .125in. (1/8)

Acrylic Pocket .125in. (1/8)

Waste Stock Bottom .1875in. (3/16)

Clamped Area at Base .125 (1/8)

Double-Sided Maze

Section View

Additional Designs

IMPORTANT NOTES -

A 1/8 acrylic plate will later be cut to fit into the space on top of the maze walls.
The clamp is holding 1/8in. of the stock.
The top side contour cut will cut down 13/16in. leaving 3/16in. at the base. When the maze is flipped, the cut for the bottom plane will be 3/16in.
The top and bottom edges, need a .03 in. chamfer as stated in the video.

Learning Fusion 360 Design and Manufacturing

Designing in Fusion 360

Video 1 - Follow this tutorial to better understand how to design how to model a part in Fusion 360.

Make sure to refer to the dimensions mentioned above when creating the maze. Follow Jake's methods when designing in CAD.

Important Note - the acrylic pocket inside corners need to have a radius (fillets) of .25in or greater. Outside corners should have filleted corners. These can be smaller than .25in.

Maze Designing - Be creative. The walls can be as narrow as .05in. but channels need to be at least .2in. in width for the ball bearings to move freely.

CAM Programming

Video 2 - Follow this tutorial to better understand the programming of the toolpaths in Fusion360 to cutting the first side on the MR-1.

When facing the top, you will be using the .5 End Mill to plane .03125in off the top. You can be creative with the angle at which it cuts.

This .5 End Mill will be used to create the acrylic pocket (.125in) as well as the edge contour. Make sure to refer to the dimensions stated above.

When cutting the maze, use the 1/8th Ball End to create filletted edges. The way it cuts into the materials is by following circular toolpaths and using one side of the bit as it spins.

Chamfer the Edge of the Top Side - Lastly, you will need to change your tool to the 1/4", 90 degree spot drill (Chamfer Mill) and create a toolpath around the outer rim of the maze. Refer to this link to learn how to properly set the tool to the toolpath. Make sure to change the Chamfer Tip Offset to 0.07 in.

By the time you are done with both sides of the maze, you should have two separate setups. Each one with three different tools. Refer to the below list for specific tools being used.

Using Simulation and See the Cutting in Action

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