Portfolio

Below are a variety of Projects I have completed in the machine shop, CNC shop and blacksmith shop.

FRISBEE MOLD

During my time in the MTT program at Shelton State, My instructor Mr. Brian Cunningham wanted to make a plastic injection mold. I had the privilege of being one of the lead designers and machinists on this project. Our class designed and built the first plastic injection mold made at the college. The injection mold makes two frisbees every time it closes and has interchangeable company logos, designed in our CNC shop, that are used for individual customizations.

Renzetti 1-2-3 Blocks

During my time in the MTT program, I found a design by Robin Renzetti for some specialized 1-2-3 blocks, so I made my own set. These 1-2-3 bocks are used as setup blocks for holding or measuring things, and the Renzetti’s particular hole pattern makes these blocks much more versatile than other standard blocks. They are case hardened to 58HRC and ground within .0002 of an inch.

US. Secretary of Education, Mrs. Betsy DeVos - Special Project

The 11th United States Secretary of Education visited Shelton State in 2018.

During my time in the CNC program in the fall of 2018, the US Secretary of Education, Mrs. Betsy DeVos, visited our school. My instructor, Mr. Jason Taylor, asked me to design and build something as a memento of her visit to Shelton State. After some thought, I designed and machined an aluminum piece, that was anodized with our school colors and engraved with the US Department of Education seal. I included a polished brass insert pressed into the aluminum. When Mrs. DeVos arrived, the CNC mill was set up so she could start the machine and watch her name be engraved.

Shelton State Paperweight

During my time in the CNC program, several faculty members needed paperweights to use when they attended conferences. My instructor gave me this item to create as a design assignment. It is a domed circular piece with extruding letters along the center of the dome that spell Shelton. These letters have a checkered pattern machined in them for texture and visual appeal.

Buck Engraving

During my time in the CNC program, I started programming on MasterCam but soon found it is limiting in the length of time it takes to design 3D models and parts.  In my research, I found the Fusion 360 CAD and CAM system from YouTube and gave it a shot. This was one of my first tests of the software’s functionality.

CAR MOLD

During my time in the CNC program, our manual instructor Mr. Brian Cunningham decided to make a second mold using the existing frisbee mold. All we had to do was make new core and cavity blocks, simple right? We found it was far from simple.

The new core and cavity blocks were made from P20 tool steel instead of the aluminum frisbee blocks. These new blocks became very challenging to machine with the very small diameter endmills we had to use.

I designed the original car model and machined the cavity blocks for the car. The mold makes one complete car every time it closes.

Multi Axis Mill Stop

In my time with the CNC program, I came across a design for a Multi-axis mill stop that I liked. I put my twist on the design and made one for myself. This design allows the device to move in a variety of directions and adjustments, and with the tightening of 2 screws, becomes an extremely rigid and reliable mill stop.

Double Lead ACME Screw

After my successful completion of both the MTT and CNC programs, I had one semester of basic classes, outside the shop left to finish, for my associate’s degree. During this time, I became the Teacher’s Assistant for the MTT & CNC programs. My grandfather wanted to make a Fly Press, which uses a very large screw and a lot of weight to create an immense amount of inertial force at the end of the screw. This gave me an opportunity to not only machine this 18″ long 2 1/2″ diameter screw but also to teach a class on manually machining multiple lead threads.

Father's Knife

I always wanted to make something special for my father with my blacksmith skills. One year for Christmas, I decided to make him a knife with my brother. This blade is forged out of a solid piece of O1 tool steel. It is ground and polished to a mirror finish and has a five-piece through tang handle. The blade has been hardened and tempered to a good spring temper around 57-58HRC.

Damascus Blade

Everyone’s favorite when it comes to knives is Damascus steel. This “pattern” steel, is achieved by taking two different materials and forge welding them together. In this case, the materials are 15N20 and 1084 carbon steel. The first material has a very high nickel content and is the brighter sections that you see. The second steel makes up the darker sections because it is simply plain carbon steel with no brightening alloys. This piece contains around 20-25 layers and is called a ‘twisted Damascus’ form.

Railroad Spike Knife

It is an interesting knife at first glance, but what if I told you it was a railroad spike at one point? It is a railroad spike that has simply been twisted while red hot to make the handle, and then the blade forged on its end. This knife can achieve around 55HRC.

Austempered Blade

This blade is special as the coloration of the blade was not created intentionally. The blade itself is forged from a piece of O1 tool steel and then ground to shape. During the heat treat process, I did something slightly different with this blade. I quenched the blade in oil as usual, but then for tempering, I used what is known as a nitrate salt bath. I do not understand everything that caused this tempering to change the color of the blade so beautifully, all I do know is that this form of tempering is considered by some to be called “austempering.” The blade is around 56HRC.

Hatchets

These are a few hatchets that I have forged out of different materials. The one in the back with the handle started its life as a rather large ball peen hammerhead. Then I forged the blade of the hatchet on one side, and the ball peen was forged square hammer on the backside.

The second one in the front was once a leaf spring under a truck. It has been folded around and forge welded in the front similar to how Damascus steel is created. Both hatchets are around 56HRC.