Xbox One Controller Phone Mount

Design files for this project can be found here: [1] [2] [3] [4]

One of the new features in the Xbox One S controllers is that they have built in Bluetooth support, making it significant easier to interface to a phone without all the hassle of having to carry around an OTG adapter. The mount itself is designed to be flexible: the phone is held securely at any angle and can be easily adjusted on-the-fly.

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CNC’d Portal Companion Cube

Design files for this project can be found here

Update 11/1/2017 – Updated design to revision C with better toolpaths

Another project on the Tormach P770: milling the Portal Companion Cube out of both 6061 aluminum and 316 stainless steel. Ended up breaking a few endmills as this was my first time milling stainless steel on the Tormach, but otherwise no major issues were encountered. Now I just need to optimize the toolpaths for a few tricky features..

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Nixie Tube Clock

Design files for this project can be found here

For the longest time now, I’ve wanted to build myself a Nixie tube clock completely from scratch. Building one isn’t easy though given the various barriers to entry: the high cost of Nixie tubes ($10-$50 each), high voltages for driving the tubes (~170V), designing the PCB, the desire for an nice enclosure that isn’t made out of laser cut acrylic.. All together, it meant that I didn’t have the time and resources to put towards this project until now.

Since I anticipate that I’ll be actively working on this project over the next 8-12 months, this post will not have the usual changelog at the top. Instead, I’ll be slowly appending my progress to this post along with any useful info I find.

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Roland Collet Fans

Design files for this project can be found here

The Roland MDX-540 that I’ve been working with gives great results when working with woods or plastics but less so when milling aluminum. While the Roland does have (barely) enough horsepower to cut through aluminum, the lack of chip clearing ends up being the limiting factor for the feed rate. While I normally use the Tormach P770 when working with metals, the Tormach lacks the nice fixturing table for mounting stock. Luckily for me, Roland provides a fan design for the NDC7S tool holder that I easily modified for a more secure fit on the collet nuts.

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Roland Fixturing Table

Design files for this project can be found here, here, and here

1/21/2017 – Update to the alignment blocks

One of the issues with the Roland MDX-540 is that it’s surprisingly difficult to mount stock for milling when not using the vise in the rotary unit. The old fixturing table consisted of an MDF sheet with a few holes drilled in it to allow it to be attached to the aluminum extrusions. Removal of the table was required to mount anything, so it was nearly impossible to mount stock with any sort of accuracy onto the table. My fix for this was to redesign and remake the fixturing table out of aluminum together with some custom clamps and alignment blocks to allow for the precise positioning of stock onto the table.

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Projects by Kevin