Jan 13 2013

3D Model with FreeCAD

The 3 dimensional model of TuxCASE for Raspberry Pi was made with FreeCAD for visual inspection. The open source FreeCAD follows a . . . show detail

The 3 dimensional model of TuxCASE for Raspberry Pi was made with FreeCAD for visual inspection. The open source FreeCAD follows a workflow similar to commercial software where 2 dimensional drawings are turned into 3 dimensional shape through basic extrude operation. Multiple 3 dimensional object can then be combined or subtracted to construct the final 3D model.

The 2D drawing from FreeCAD can also be exported as DXF to be opened in LibreCAD for tool path calculation.

Note: Currently, FreeCAD v13r1335 is metric only. However, LibreCAD can convert the FreeCAD generated DXF file from millimeter to inch.


May 22 2012

Initial Production Summary

TThe initial batch of the bottle opener has been completed and mailed out. After numerous revisions, only . . . show details

The initial batch of the bottle opener has been completed and mailed out. After numerous revisions, only 12 pieces of blanks were left for the final revision. Therefore, out of 100 blanks only 12 acceptable bottle openers were produced.

There first couple revisions had too shallow of a mouth opening that caused the bottle opener to peel the edges ofthe bottle cap. Subsequent revisions were made to lengthen as well as deepen the mouth opening to give better mechanical leverage. Electrochemical etching was inconsistent and was replaced with direct laser marking.


May 04 2012

Haas SR-100 Vacuum Table

A two way solenoid valve was installed to enable the control, through CNC Controller M-Code, of opening and closing the pneumatic 5C collect chuck.  A roller lever switch, wired in parallel, was also added to the boot padel, to enable manual control.


Apr 26 2012

Bottle Opener Revision 5

The mouth opening was increased from a radius to .100" to .110" to better accommodate taller caps.


Apr 25 2012

Bottle Opener Revision 4

The shallow mouth opening has too steep of an angle and tends to . . . show details

The shallow mouth opening has too steep of an angle and tends to peal the cap back. The mouth opening was elongated to give better leverage to lift the cap.


Apr 24 2012

Initial Production Batch

Turing the initial prodcution machining, the machining speed and feed parameters used during prototyping was . . . show details

During the initial prodcution machining, the machining speed and feed parameters used during prototyping was slowly increased. Gradually, the machine time per bottle opener was reduced from18 minutes to 15 minutes. The vibratory deburing took another 4 hours and tumble burnishing takes around 2 hours. The logo engraving process takes another 5 minutes.


Apr 23 2012

Bottle Opener Revision3

The mouth lip was modified for better clearance and the center cavity was removed to help . . . show details

The mouth lip was modified for better clearance and the center cavity was removed to help speed up the machining process and the logo were modified to reflect the coarser resolution of electrochemical etching. The height was also reduce to better fit the raw stock height.


Apr 21 2012

ElectroChemical Logo Etching

An electrochemical etcher was used to explore using etching the Tux-Lab logo on to the Stainless Steel bottle opener. . . . show details

 

An electrochemical etcher was used to explore using etching the Tux-Lab logo on to the Stainless Steel bottle opener.

Electro-Chemical Etcher - McMaster
Starter Kit 2amp Hand Marker $73.80
16oz Stainless Steel Electrolyte $10.77

Apr 19 2012

Post machining deburring and polishing

Tumbling with the ceramic media on the left . . . show details

Tumbling with the ceramic media on the left will deburr and slightly round the sharp edges. Burnishing with the porcelain media on the right will brighten the surface dulled by the deburring process.


Apr 13 2012

Prototype Machining

Stock - Metal Express
304ss flats, 4” x 0.5” x .125”, 100pc @ ~1.865 $86.00


Tooling - Martitool
.125 Double End 4F Carbide End Mill TiAlN, 2 @ 8.51 $17.02
.250 Double End 4F Carbide End Mill TiAlN, 1 @ 14.82 $14.82
45 deg Shell Mill Insert, ACK300 grade, 5 @ 10.70 $53.50


Fixture – HomeDepot
6-32 Hex Socket Screw $0.65
10-24 Hex Socket Screw $0.86
6-32 Irwin Drill/Tap Kit $4.97
10-24 Irwin Drill/Tap Kit $5.47


Tooling – Martitool, 2nd Batch
.125 Double End 4F Carbide End Mill TiAlN, 4 @ 8.51 $34.02
.250 Double End 4F Carbide End Mill TiAlN, 2 @ 14.82 $29.63
.125 4F Carbide Drill Mill 120Deg 1 @ 8.44 $8.44
3.3mm .1299” Cobalt 130deb Screw Length Drill TiAlN 2 @ 7.58 $15.16
USPS Priority Mail $12.45