M Musaed AlKout

Computer-Controlled Machining

Fab Academy style documentation for designing, machining, and assembling a large-format CNC project using the same theme and layout as the rest of the site.

Assignment

Computer-Controlled Machining

Machine

CNC Router

Material

MDF

Output

Press-fit / assembled object

Goal: Design and machine something large using computer-controlled machining, then assemble and evaluate the final result.

🧠 Learning Objectives

  • Understand the workflow of large-scale CNC machining.
  • Prepare a design suitable for machining and assembly.
  • Generate correct toolpaths and use safe machine settings.
  • Assemble and evaluate the machined parts.

📌 Documentation Requirements (Checklist)

  • Show the full workflow

    From design to CAM, machining, and final assembly.

  • Document machine settings

    Feeds, speeds, bit size, pass depth, tabs, and workholding.

  • Include evidence

    Screenshots of design/CAM and photos of machining and assembly.

  • Provide files

    Design files, toolpaths if possible, and notes.

🛠️ Tools & Materials

  • CAD Software: Inkscape
  • CAM Software: Inkscape
  • Machine: CNC router (TwoTrees TT450 Pro)
  • Cutting Bit: 1/8 inch Downcut end mill - To produce nice clean cut
  • Material: 5.5mm / MDF
  • Finishing Tools: Sandpaper, mallet, clamps

Safety reminder: Wear eye protection, secure stock properly, check zeroing carefully, and never leave the machine unattended while cutting.

📐 Design Process

I started by designing a machinable object that could be cut from sheet material and assembled afterward. Since the CNC router uses a round tool, I considered internal corner limitations and added the required machining allowances.

  • Material thickness: measured the real board thickness before designing slots.
  • Press-fit logic: slot size was adjusted based on actual material thickness and tolerance.
  • Nesting: arranged parts efficiently on the stock sheet.
CAD layout of the parts before export to CAM.
Replacing the drill bit
Image of available drill bits
Checking Material Thickness
Locking the material to CNC plate
Measuing the Z distance using the sensor of the CNC Machine
Probing the Z distance sensor
Getting read to start
CNC in action :)
CNC Vacuume

⚙️ CAM Setup

After finalizing the design, I imported the geometry into CAM software to create the required toolpaths.

Parameter Value (Example) Purpose
Bit Diameter 3.175 * v30 degrees Three edged sharp knife Bit
Cut Depth Material thickness + small extra Ensures the cut goes fully through the stock.
Pass Depth 5.5 to 6.0 mm Controls depth per pass for safe cutting.
Feed Rate 30in/min Machine movement speed during cutting.
Spindle Speed 12000 RPM Controls tool rotation speed.
Toolpaths in CAM software
Toolpath preview showing profiles, tabs, and cut order.
CAM simulation preview
Simulation preview used to verify the machining sequence.

🪚 Machining Process

  • Secured the sheet material properly on the machine bed.
  • Installed the correct cutting bit and tightened it securely.
  • Set X, Y, and Z zero positions carefully.
  • Ran the job while monitoring cutting quality, chip removal, and safety.

Check before cutting: spindle on, correct origin, correct units, correct depth, and safe toolpath preview.

CNC machine setup before cutting
Material fixed on the bed and machine prepared for cutting.
CNC router cutting the parts
Machining in progress on the CNC router.

🧩 Assembly

After machining, I removed the parts, cut the tabs, cleaned the edges, and tested the fit of the joints.

  • Removed tabs and cleaned rough edges with sanding.
  • Tested the slot fit and adjusted where necessary.
  • Assembled the final structure using press-fit joints / fasteners (replace as needed).
Machined parts after cutting
Cut parts removed from the sheet after machining and assembled

✅ Results

Replace placeholders with your final project images and measurements.

Final assembled CNC machined object
Final assembled object after machining and finishing.

⚠️ Issues & Fixes

  • Rough cut quality: checked feed, speed, bit sharpness, and pass depth.

📦 Downloads

Add your real files below and place them in the same folder as this page.

Design File (Easel File) Design File (SVG File)

Reflection — What I Learned

  • Material thickness must be measured in real life and not assumed from the label.
  • Good CAM setup is just as important as the design itself.
  • Dogbones and machining allowances are essential for proper assembly with CNC-cut parts.
  • Testing fit and documenting machining settings makes future iterations much better.