Initial Design

For my initial design, I wanted to create a hammer with both functional and aesthetic features. I added a detailed grip pattern on the handle using a series of evenly spaced grooves. This not only improves the user’s grip but also adds visual interest to the part. I filleted the edges of the hammer head to give it a smooth, clean appearance and to reduce sharp transitions that could weaken the part, or potentially cause injuries. 

To ensure everything fit within the stock material, I carefully adjusted the overall size and left a 0.400" gap between the part and the stock border. This provided enough clearance for the cutting tools to operate safely without damaging the part or the fixtures. For the tab placement, I used larger tabs around the hammer head for extra stability, since it has more mass and needs to remain securely in place during machining. Along the handle, I alternated smaller tabs to hold the part while still allowing the intricate grip details to be machined cleanly.

The frame around the part helped keep it secured and well-supported throughout the process. Overall, this setup allowed me to cut the part safely and efficiently while achieving a clean, finished result.

As part of our overall machining plan, we intended to use a dovetail cutter to create a dovetail joint in the stock, which would allow the part to be securely attached to the trunnion for 4-axis machining. However, I did not include the dovetail feature in my initial design. This would later change in my redesign, where I integrated the dovetail geometry to better align with our fixture and setup strategy. 

Final Design

As you can see, my final design is much more visually appealing and refined. I decided to completely restart the project from scratch because the original model had become too complicated and difficult to manage. With help from my teammates at AMLA, I was able to clean up my workflow and rebuild the project efficiently. Surprisingly, I completed the redesign in about 20 minutes compared to the full day it took to conceptualize and build the original hammer. That felt like a major personal milestone, as I could clearly see my growth in efficiency and proficiency with 3D modeling tools.

For the final version, I removed the complex grip design from the handle. While it was a cool concept, it would’ve been difficult and time-consuming to program and machine. Ironically, the simplified version ended up looking much cleaner and more professional. I also optimized the tab placement with input from my shop floor manager, who pointed out that my original tabs were inconsistent and excessive. With his guidance, I minimized the number of tabs and placed them more strategically, improving both the part’s stability and the machining process.

Additionally, I smoothed out the transition between the handle and the hammer head, opting for a more minimal and cohesive connection. This subtle change significantly improved the overall aesthetic of the design. In the end, the redesign wasn’t just about making the part easier to machine—it was a reflection of how much I’ve improved as a designer and machinist.

Camming

 For the CAM process, I used a combination of toolpaths to ensure both efficient material removal and a smooth final finish. I started with adaptive clearing to remove the bulk of the material quickly and efficiently, especially in deeper areas where roughing was needed. This allowed me to maintain consistent tool engagement and reduce machining time.

To smooth out the contours and eliminate the visible steps left by the flat end mill, I used parallel finishing passes along the outer surfaces. This gave the part a much cleaner and more refined appearance. For the curved and detailed edges, I used a ball nose end mill, which helped blend transitions and create smooth surface finishes that would have been difficult to achieve with a standard flat tool.

Lastly, I used a ramp toolpath to finish off the side profile of the part. This approach allowed the tool to gradually descend into the material, reducing tool load and leaving a cleaner surface along vertical or angled walls.

Check out the file!