Caliper Box Commission - Laney College Machining Dept.
As Assistant Manager of the Laney FabLab, I was personally commissioned to manufacture 35 hardwood caliper boxes for long-term use. The boxes were intended to improve durability and perception of the calipers’ value, reducing yearly losses due to damage.
Due to the large production scale, I managed a team of student workers in order to meet project deadlines. The process of mass manufacturing a product under budget and time constraints kindled my interest in the field of manufacturing as well as project management.
Prototyping Process
Prototype 1: A 2D contour was designed in Fusion 360 and laser cut in MDF to test fit. After refinement, the contour was approved by the department chair.
Prototype 2: Contours and hinge pockets were added and cut paths implemented via Fusion 360 CAM software. A prototype was milled on the ShopBot 3-axis CNC in MDF.
Prototype 3: After final approval, a single unit in maple hardwood was milled, allowing refinement of CNC feeds and speeds, cut paths and depths, and wood thickness.
Milling and Finishing Process
Hinges, clasps, and hardwood boards were sourced and purchased.
Layout was optimized on the hardwood and each piece CNC milled (70 pieces total included top and bottom).
The lid was designed in Abode Illustrator and laser engraved.
6 protective layers of urethane were added with light sanding after each layer.
Adhesive felt matching the pocket contour was laser cut and applied.
Clasp holes were machined using a Bridgeport mill, then clasps and hinges installed.
