To address the common issue of cluttered workspaces in machining environments, I designed a compact organizer to help machinists keep essential tools—such as scanners, badges, and small items—neatly arranged and easily accessible. The goal was to create a functional, efficient, and aesthetically pleasing solution that would streamline workflows and reduce misplaced tools. Below is the evolution of my design process.

Design Evolution

Version 1 (Initial Concept):

• Badge Slot:

  • The initial version (unfortunately, the CAD model was lost) featured a small oval blind hole to hold a badge. However, this simple design lacked functionality and refinement.

  • The badge slot was redesigned with three ½-inch holes, spaced 10mm apart, at different depths: one through-hole and two blind holes. This iteration proved impractical as the part was too large to be machined in a single operation.

Version 2:

• Badge Slot:

  • Reverting to the oval-style through-hole for simplicity, I enlarged the hole to accommodate various badge sizes.

• Scanner Holder:

  • Adjustments were made to the height difference between the step and the blind hole, ensuring the scanner sat securely. The blind hole was raised 0.020 inches above the step for improved functionality.

• Pocket Design:

  • A small pocket was added to store bolts, screws, and other small items, rounding out the design as an all-in-one organizer.

Version 3 (Finalized Design):

• Focus Shift:

  • Inspired by feedback from a mentor who often misplaced his torque wrench, I replaced the badge holder with a dedicated slot for a torque wrench. This change addressed a critical need on the shop floor.

• Pocket Redesign:

  • The pocket was enhanced to hold small items like bolts and screws. To increase versatility, I introduced a stepped design with two elevations: one at ½ inch and the other at ¾ inch. Smooth fillets were added to the corners for better aesthetics and usability.

• Scanner Holder:

  • This feature remained unchanged, retaining its secure and functional design.

Outcome:

The final organizer effectively combines functionality and aesthetics, offering a designated place for essential tools such as scanners, torque wrenches, and small items. The scanner holder performs its task flawlessly, the torque wrench slot provides a secure resting place, and the redesigned pocket accommodates various small tools and hardware.

Through iterative design and hands-on machining, I gained valuable insights into refining concepts, optimizing stock setups, and ensuring manufacturability. The finished product not only meets the needs of machinists but also enhances workspace organization, reducing clutter and improving efficiency.

After completing the simulation of the cammed part, I loaded the G-code and carefully reviewed the feed rates to ensure the machine would operate safely and effectively. Once confirmed, I downloaded the G-code onto a USB drive and transferred it to the pendant of a 3-axis CNC machine.

To prepare the machine, I removed the existing jaws using a 3/8-inch torque wrench and installed new jaws better suited to securely hold my part. After setting up the machine, I located and opened the G-code file. I then used a probe to set the offsets by touching off the X and Y axes at the origin point, located at the bottom-left corner of the part.

Before running the program, I positioned my thumb over the stop cycle button as a precaution. The program ran smoothly from start to finish without any issues.

After machining, I printed the blueprint of the part, which included a top view and two sectional views to illustrate the different elevations of the design. I measured all the specifications of the part myself to ensure accuracy and then sent it to inspection for verification. This process allowed me to confirm that my measurements aligned with the design requirements before final approval. When i got the part and blueprints back, i saw that i was in tolerance for all of my specs except for the height on the 3/4 hole, which was .002 out of tolerance. The inspectors measurements are boxed, my measurements are in pencil, and the actual measurements are printed in black ink.