Computer-Controlled Machining
CNC Machine
This time, we weren’t just loading files and pressing "Start." We got into the software side, made proper settings, and actually understood what was happening.
Group Assignment
A. Setting Up the File
We started by bringing our design into (software name—VCarve, Fusion 360, etc.) and checking a few things:
File format – DXF or SVG worked best.
Material size – Because if the software thinks our wood is 10mm thick and it's actually 12mm… well, that’s a problem.
Toolpaths – We set whether we wanted pocket cuts, profile cuts, or engraving.
B. Toolpath Settings (a.k.a. Making Sure It Cuts Right)
Once the design was in, we set up how the CNC should cut:
Bit selection – 'Flat-end' for clean cuts, 'ball-end' for curves, 'V-bit' for engraving.
Feed rate & spindle speed – Too fast? Bit breaks. Too slow? Material burns. We found a balance.
Depth per pass – Instead of forcing the bit to cut everything in one go (bad idea), we set it to cut in layers.
Tabs – So our cut parts didn’t suddenly pop out and get hit by the spindle.
C. Setting Up the CNC Machine
Once the file was good to go, we moved to the machine:
Zeroed X, Y, Z – Either manually or using the probe. No one wanted the bit slamming into the material.
Previewed the cut – To catch mistakes before ruining our stock.
Loaded the right bit – Because using the wrong one = chaos.
With everything set, we ran the job and watched closely. No weird noises? Material staying put? Good.
Definitely felt more in control this time—less guessing, more knowing what’s actually happening!
D. CNC Safety Measures
Personal Safety First
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Wear safety goggles – Tiny chips fly fast, and eyes don’t grow back.
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No loose clothing or jewelry – The spinning bit doesn’t care if it’s your favorite hoodie.
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No gloves – Hands have better control without them, and gloves can get caught in the machine.
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Closed-toe shoes only – Because dropping sharp tools on your foot is not fun.
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Tie back long hair – Unless you want the CNC pulling you in (which you don’t).
Machine Safety Checks
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Bit properly tightened – A loose bit can fly out like a projectile.
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Material is clamped securely – If it moves mid-cut, things go wrong fast.
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Speed & feed rates checked – Too fast? Bit breaks. Too slow? Material burns.
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Dust & chip control – Kept things clean so we could see and breathe properly.
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Zeroing X, Y, Z correctly – So the CNC knew where to start and didn’t crash into our stock.
After the Cut
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Turn off the spindle before touching anything.
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Clean up chips and dust with a brush or vacuum.
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Check the bit’s condition – If dull, replace it before the next cut.
These were few protocols we followed throughout our course.
Individual Assignment
Prior CNC Furniture: Designing, Cutting & Assembling from Scratch
The objective of this project was to design and fabricate a functional and sturdy desk using 18mm plywood. The design focused on simplicity, ease of assembly, and efficient material usage. The desk is intended to serve as a general-purpose workspace, suitable for home, study, or office environments, with consideration given to ergonomics, durability, and clean aesthetics.
A. Sketching in Fusion
Initiated by creating the basic layout, marking out all the parts with their measurements to ensure everything would fit together properly.
B. Extruding
extruded the base of the table along with the side panels and the top surface to give them the required thickness and create the 3D parts. modeled a pull-out tray (drawer) that fits smoothly within the side panels, allowing easy access and additional storage space under the tabletop.
C. Making Drawer/ Pull out tray
modeled a pull-out tray (drawer) that fits smoothly within the side panels, allowing easy access and additional storage space under the tabletop.
D. Column for Balance
The desk has six support columns for balance, arranged as three on each side, with a T-shaped base to provide extra stability.
E. Manufacturing
arranged the parts efficiently on a sheet to minimize material waste. After finalizing the design
the cutting files in the required format for CNC machining or manual cutting.
used the CAD drawings as a reference during the fabrication and assembly stages to ensure everything fit correctly.
F. Hero Shots of Furniture
Abstract CNC Furniture: Lamp
A. Initial Idea and Concept
I’m designing a wooden floor lamp that doesn’t need any nails, screws, or glue—just an interlocking mechanism that holds everything together. The structure is entirely self-supporting, with smooth, organic curves that aren’t just for looks but also help balance the weight naturally.
The whole idea is to treat furniture like a puzzle—fun to assemble, visually unique, and structurally clever. It’s an experiment in form, function, and balance, using only the precision of interlocking wood to keep everything in place.
Inspiration
B. CAD
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Created a long, curved wooden lamp design using Fusion 360.
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Lamp dimensions: 1200 mm length × 30 mm width.
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Material thickness: 12 mm plywood.
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Design focused on smooth curves and interlocking joints for glue-less assembly.
Created circular shaped attchments with slot of 12mm to 30mm with 180mm as diameter for base of lamp.
Each panel is 1200mm to 100mm
Made slot on bottom, then extruded to 12mm which was thickness of material. then, follow the rectangular patter along the axis
Base for making curves
Hid unwanted bodies from panel after splitting with Split Body tool
Extruded intersection for top part panel so it fits to circle accordingly
Placing th components on size of machine bed and 3inch offset
Alligning panels to each other
It was important to bring parts on same axis by alligning them to each other
Followed this tutorial while making curves. Youtube
C. Measurement
| Part Name | Length (mm) | Width (mm) | Thickness (mm) | Quantity | Notes |
|---|---|---|---|---|---|
| Lamp body panel | 1200 | 30 | 12 | 1 | Main curved panel |
| Interlocking tabs | Varies | Varies | 12 | Multiple | Designed into edges |
D. Machine
The CNC machine used is a Numac Hitech model with a working area of 2400 mm by 1200 mm, allowing for precise cutting of large plywood sheets up to those dimensions.
E. CNC Toolpath Preparation in Fusion 360 – Student Documentation
After completing the full 3D design of my pinball table, I shifted to the Manufacture workspace in Fusion 360 to generate the toolpaths for CNC cutting. The aim was to convert the digital design into accurate and safe G-code for cutting all the parts out of a single 4 ft × 8 ft plywood sheet—focusing only on profile cuts, with no drilling or dowel holes.
1.Setup Creation
I began by creating a new setup. I selected the full plywood sheet model as the stock and set the dimensions to match the actual sheet: 2440 mm × 1220 mm × 12 mm.
I chose the top-left corner of the sheet as the origin point (X and Y zero) and set the top surface of the sheet as the Z-zero. This matched the way the sheet would be placed on the CNC bed.
2.Tool Selection
I used a 6 mm up-cut router bit, ideal for clean plywood cuts. I added this to my tool library and entered appropriate feed rates and spindle speed based on the CNC machine and material I was using.
3.2D Contour Operations for Cutting Profiles
design didn’t involve any holes or pocketing, I went straight to 2D Contour:
selected the outer edges of each component as cutting profiles.
Enabled tabs (around 3 mm thick and 6 mm long) to make sure parts stayed connected to the sheet during machining.
Set the cut depth to slightly beyond 12 mm (around 12.2 mm) to ensure a clean cut-through without damaging the machine bed.
4.Toolpath Order & Strategy
To avoid any shifting during the cut, I made sure internal parts were cut before the outer profiles. I arranged operations to follow a logical sequence that maintained sheet stability throughout the process.
5.Heights & Linking Adjustments
I increased the clearance height to avoid any potential clamp collisions.
For smoother cuts, I added short lead-in and lead-out arcs, which helped reduce visible tool marks at the entry/exit points of the bit.
6.Simulation
I ran a full simulation in Fusion 360 with the stock view turned on. This helped me double-check that the toolpaths followed the correct order, tabs were placed correctly, and there were no collisions or errors.
7.Post-Processing
Once everything looked good, I post-processed the toolpaths using the GRBL-compatible post for our Numac Gitech CNC router (2400 mm × 1200 mm bed size). The output file was saved as Pinball_CutOnly.nc and transferred to the machine
clamped the plywood firmly onto the CNC bed, aligned the origin to the corner, and zeroed all axes. I ran a dry pass without cutting to confirm tool movement, and then started the actual machining process.
8.Cleanup & Assembly
After cutting, manually lightly sanded all edges. Since the design relied on interlocking joints, no glue or screws were needed. All parts slotted together snugly, just as planned.
Have uploaded NC File of lamp to check with settings directly.
F. Manufacturing
After cutting the parts, I sanded them to smooth out rough edges and did some finishing to give the surfaces a clean look. Then, I adjusted the pieces to make sure everything fit perfectly. Once that was done, I moved on to assembling all the parts together to build the complete lamp. After assembly, I checked everything to make sure it was sturdy and looked good.
Fastening wooden ply on bed, placing a coolant, setting up machine with axis, cutting, polishing, assembling
The slot fit perfectly, also added a placeholder for bulb
Hero Shot
