computer-controlled machining

This week we learn how to create a Fusion file for CNC milling, transforming a 2D design into a 3D product. I designed a laptop table for our FabLab, assembled without glue or screws.

Design Preparation

I created a new component in Fusion 360 and inserted a photo showing the parts of a laptop standing desk. This image served as a reference for my sketch.

I then sketched the geometry of the individual parts over it and defined various parameters to keep the design flexible.

I set the material thickness to 12 mm, as this is our standard wood panel thickness. Afterward, I extruded the sketches to create a 3D model of the desk.

Test Milling and Adjustments

Before starting the actual milling process, I milled test cutouts to determine the optimal kerf size (cut width). This was crucial to ensure that the boards fit together perfectly.

I tested different spacing options to find the best fit. I found that two different cutout dimensions were necessary:

The connections of the base should have a steeper angle.

The tabletops holding the laptop or keyboard should have a less steep angle, requiring a slightly wider gap.

After these tests, I adjusted my parameters in the final laptop desk model accordingly.

Setup for the Milling File

Once the design was complete, I created two milling models and arranged them on the wood panel to optimize material usage.

For both models, I created a setup in Fusion 360, setting the offset to 0.1 mm to compensate for unevenness in the wood panel.

Then, I selected the 2D contour machining:

First, the inner contours to ensure that the cut-out parts do not shift later.

Then, the outer contours.

I worked with an 8 mm milling cutter, which I added to the tool library.

If necessary, I added tabs (holding bridges) to prevent the parts from coming loose during the milling process.

These tabs were positioned so that they were not in tight corners or curves, making them easy to remove later.

Additionally, I enabled multiple depths to gradually remove the material.

After finishing these settings, I used the simulation mode to verify that the milling process would run smoothly.

I then saved the post-process. Before sending the file to the milling machine, I opened it as a text file and added the M8 command to ensure that the dust extraction system starts automatically.

Milling Setup and Execution

The milling file was loaded onto the milling computer.

The milling machine was calibrated.

Than i checked the origin.

The file was shifted 10 mm from the panel edge to create a buffer zone.

A safety check was performed before starting:

• Activate dust extraction

• Turn on compressed air

• Ensure the wood panel is correctly positioned

• Confirm the milling cutter is in the correct holder

• Put on hearing protection

• Have the remote control ready

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The milling process was then started. In the first few seconds, I monitored whether everything was running correctly.

Only after confirming this did I lower the dust extraction system to continue observing the process.

Once the milling was complete, I turned off the machine to unlock the safety doors. I then removed the parts from the panel and cut the tabs using a sculpting tool.

Post-Processing

The tabs were removed using an edge router.

All sharp edges were rounded.

The entire object was sanded.

A first coat of fireproof varnish was applied.

After drying, it was sanded again and a second coat of varnish was applied.

With that, the laptop standing desk was completed and ready for use.

For the Fusion file of my project click here