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Olson Manufacturing – Featured Customer

Featured Image Courtesy of Logan Olson, Olson Manufacturing

Located in northern California, Olson Manufacturing specializes in handcrafted, customizable golf products that are made with utmost attention to detail from the highest quality materials. Logan Olson, its owner, was introduced to the game of golf by his grandparents at a young age and fell in love with the sport, especially how individualized it is, and how one’s own effort and dedication is paramount. It is because of this love of golf that Logan began designing, and making, his own putters. Soon after, Olson Machining was born.

Now with years under his belt, Logan took time to reflect about Olson Manufacturing, his passion for golf, high-quality tooling, and where his inspiration for his designs originated.

Photo Courtesy of: Logan Olson, Olson Manufacturing

How did you get started and learn how to machine?

I got started in manufacturing coincidentally with making putters: A project that went from a solely digital design to learning a CAD program. It turned into something I wanted to bring into tangible space. A friend of mine introduced me to a manual machinist that had a small machine shop at his house. He had just purchased a personal hobby-sized CNC machine and was kind enough to let me hobble my way through learning the fundamentals of machining on it to design a putter. A year later, I held a barely recognizable chattery mess of a putter and my journey was just beginning.

Where does your passion for golf come from?

I was introduced to the game of golf early on by my grandparents. The individual nature of the game, surrounded by the need to depend on your own effort and dedication as a means to success, has really paved the way for me as a business owner. The need for honesty and integrity, even when it might be easier to take the other road out, has allowed me to stick through the challenging aspects of creating a machine shop and allow my business to thrive in this fast pace, ever-changing world.

What is the inspiration in your designs?

From a design aspect, my number one priority is to do my absolute best to execute the task of creating the best putter I can for the end-user. Customization, additional design aspects, as well as other details, are a welcome addition to a putter that will perform at the highest level. When it comes to the design of creating a custom build, I try to forget that the piece I am working on is a putter altogether and pull my inspiration from other places and different crafts.

It’s always fun when people ask what I do as a machinist to tell them I make golf clubs. There’s always a hesitant humorous laugh as they respond with an, “oh that’s nice, or good for you”. That always seems to change as soon as I show them what I actually make.  The following response is usually more on the stream of “you seriously make these, or wow, that’s not at all what I expected.” The detailed craftsmanship of sword makers, clockmakers, and jewelers is where I try to pull my main inspiration from.

 I do a lot of commissioned work for customers ordering a specific putter that they themselves design, however, I think my true voice as an artist and machinist lies with the putters I make where the designs can flow out of my own imagination with no guidelines or restrictions.

What is your favorite putter you’ve designed?

I’ve had the opportunity to create a ton of really cool and unique projects in my years as a putter maker. It’s really hard to pick out a favorite. I try to say that my favorite putter I’ve ever made is the one I’m currently working on or excited about. I could probably make a list of the top 20 maybe, but picking an individualistic favorite would be tough.

Who is the most famous contact that you have worked on a project with?

I’ve been lucky enough to work with a handful of professionals on the PGA tour as well as the LPA tour and Web.com tours. Feedback from this caliber of players is really the driving force of development for what I do. They can offer some of the most keynotes that help drive changes every year. I have a hard time picking apart a favorite project, but every time a professional golfer comes aboard I always seem to learn something new.

What sets Olson Manufacturing apart from the competition?

In a world where mass production and system efficiency control the consumer market, utilizing old world craftsmanship in companion with cutting edge technology, I can create one of a kind personalized and unique products. That’s not a touch you can find buying something off of a shelf. Knowing that only 1 pair of hands might have spent hours, days, even weeks just creating a putter, I think is something a person holds value to once they acquire one of my putters.

What machines do you currently have in your shop and what materials are you machining?

I use all vertical mills at my shop. With the exception of one of my largest machines, having a 4th axis. Everything I run is all 3 axis machining. I really cut everything under the sun. The bulk of my machining consists of stainless steel, mild alloy carbon steel, and aluminum, for fixture making. However, with that said, I do a very large amount of copper as well. The bulk majority of my inlay work is done in superalloys and some exotic blends such as Zirconium-Titanium alloys, Titanium Damascus (Timascus), pre-hardened high carbon Damascus steels, mother of pearl, bronze, and a handful of other materials.

Why is high quality tool performance important to you?

When I’m working in an environment where the part I am making is a one-shot kind of deal or the material is incredibly hard to get/ expensive, not having the ability to remake the part is why customer support and applications engineers are indispensable. When you’re off purchasing a cheap tool from an unknown company you are unlikely to be able to pick up the phone and say “hey, I’ve got a .030” tool going 1” deep in titanium, this tool can’t break haha can you help me out?”

I can count back just in the last year at least a dozen times I’ve spoken with a Harvey Tool rep on one of my micro tools for a cutting recipe recommendation for an application that kept me out of the dog house. I think we could all talk about coating, cutting life, and tool performance all day long, but I could argue that being able to make a phone call and have an engineer reassure you something will work, is the most important thing of all when it comes to quality tool performance.

What is the smallest Harvey tool you have used and the largest Helical tool?

I’ve used a .02” diameter 3 flute tool for stainless and carbon steel, which would likely be the smallest. I regularly store a .04” tool in my tool changer for pocketing on small inlay work. I used to be scared to sneeze on them in fear of them breaking, now they’re as dependable as any tool in my library and I require them daily for all kinds of machine work. The largest tool I run from Helical is a 6 flute ½” endmill for HEM roughing. I find that’s really as large as I need to go.

If heavier cutting is necessary I’ll lean on an insert tool. I really think some people would be amazed though, at the MRR you can get with a ½” tool. These modern toolpaths are incredibly powerful in comparison to some of the older style machining strategies. Give me a ½” tool in stainless full depth at 250 inches a minute and I can move some metal.

Can you talk about a time that Harvey Tool or Helical products really came through and helped your business?

This would go back to one of my earlier answers for the customer support argument. I was running a billet of pre-hardened Damascus steel for a putter I was making. I don’t know if you’re familiar with Damascus at all, but if you picture high carbon steel blended, smashed, and forged together with a nickel alloy, then hardened, I think you can paint a picture. Oh yeah, and nickel alloys are famously fun to machine… think Inconel, Monel, and Hastelloy… fun stuff. So take that billet and make a putter out of it haha.

Anyways, this stuff is harder than a coffin nail and is eating my 80 dollar endmills for breakfast like it skipped dinner the night before. I was down to my last ½” tool that could do the machine work on this putter and didn’t know what I was going to do. I called up Helical, and an applications engineer not only gave me a recipe that ended up saving me but sent me the skew for a tool that worked way better than the one I had in the spindle. I ordered a package of them, and ever since that day, they are my go-to in Damascus.

If you could give one piece of advice to a new machinist ready to take the #PlungeIntoMachining, what would it be?

My biggest piece of advice would be to learn as much as you can. In today’s world, the internet is an incredibly powerful tool and platform for the machining community. There is basically a video out there somewhere you can watch that can probably answer any question you might have. It’s insane. I’m 24 years old and started as a machinist at 19-20. There is absolutely no way I could have gotten to where I am today without countless hours of YouTube scrolling and video binge-watching. It’s great stuff and you should soak it in like a sponge as fast as you can. 30 years ago the machinists would look at the stuff we are doing today and call it Wizardry. We truly are living in an incredible time. Live, learn and love what you do.

To see more of Logan and Olson Manufacturing, you can follow him on Instagram @olsonmfg

Defiant CNC – Featured Customer

Featured Image Courtesy of Jeremy Taylor, Defiant CNC

Twenty years ago, Jeremy Taylor worked as a Tool and Die Apprentice and was well on his way to earning his Journeyman Certification, when he fell in with the wrong crowd and found himself in trouble, criminally. As a result, he found himself facing a lengthy prison sentence but was determined to make his time incarcerated as constructive as possible. During his sentence, he earned his undergraduate and MBA degrees, taught himself Spanish and Italian, and used his limited access to computers to stay updated on all things CNC machining, including the evolution of tool making and advanced manufacturing.

Today, Taylor owns Defiant CNC, a 2-year-old machine shop located in Orlando, Florida, that specializes in performing a wide variety of machining operations, including CNC Milling, CNC turning, laser engraving, finishing, quality control, CAM/CAD, inventory management, technical drawings, and ERP services. Defiant CNC machines everything from components for underwater welding robots to tools for helicopter repair kits, to even tools for pastry decorating and jewelry making.

Along with owning his business, Taylor also spends his time working with The Community, a company that focuses on preparing prisoners to reenter society.

We spoke with Taylor to learn more about how he changed his life’s trajectory; his new business; the ERP system he built, himself; and what he values most in CNC tooling, among other topics.

Photo Courtesy of: Jeremy Taylor, Defiant CNC

How did you first get started in machining?

I started off as a Tool and Die Apprentice. I was making tremendous progress towards my Journeyman Certification until I got myself into trouble. I had done a great job of learning very sophisticated toolmaking techniques and CNC programming/machining. Unfortunately, when I was a few months away from obtaining my journeyman’s card, I was incarcerated for 14 years. However, I utilized that time to significantly change my life trajectory. While in prison, I taught myself Spanish and Italian, kept as up to speed as I could (given very limited access to computers) on the evolution of tool making, CNC machining, advanced manufacturing, computer hardware, and software, completed both an undergraduate degree and an MBA via a mixture of mail and online access.

Today I am a completely different person than the one who wasted the great opportunities I had before my imprisonment. Somewhere along the line during the time when I was 18-19 or so, I fell in with the wrong people and took a path that led to me wasting what should have been the best years of my life. Rather than give up, I used that time while confined to continue my education and prepare myself for a productive role in society after my release. Getting back into machining played a huge role in my current success. Defiant CNC has only been in business for a little over two years, but the best is yet to come.

Photo Courtesy of: Jeremy Taylor, Defiant CNC

What machines are in your shop?

Defiant CNC currently has 4 mills: Doosan DNM 4500, Chevelier QP 2040, Toyoda Stealth 1365, and a Manual Bridgeport Mill. We use Fusion 360 on all of our milling machines. We also have 5 lathes: Emco Maier 365 Y, Miyano BND-51S, Miyano BND-20S5, Miyano BND-34S. and a Miyano BND-42S. Finally, we have our two support machines, a Cosen MH-1016JA Bandsaw and a Boss FMS Laser for Desktop Fiber Marking.

What industries have you worked with?

We have worked with a large variety of industries, including aerospace, defense, automotive, commercial, and medical. Working in these industries allows us to machine in all different materials: Aluminum (7075, 6061, and 2024), Stainless Steel (303, 304, and 316), and Steel (1018, 4140, and 1045).

Photo Courtesy of: Jeremy Taylor, Defiant CNC

What sets Defiant CNC apart from the competition?

We provide an array of machining-related services including milling, turning, CAD design, engineering, and laser engraving in-house. We also provide a number of services through vetted partners such as heat treating, welding, and plating. However, what sets us apart from the rest of the competition is the Enterprise Resource Planning (ERP) system that I built, which is customized specifically for our shop. Not only does it allow us to streamline our operations, but it also allows us to give that something extra to our customers. I create portals and give our customers access to all their past and present jobs with us. They can check the status of any of their jobs as they move through the production process. We take just as much care managing every aspect of the business as we do machining parts.

Typically in small-to-medium-sized shops, the data structure is to create a series of customer-job-part revision folders, and put the customer data there. This data structure is rarely planned for growth. I created an Enterprise Resource Planning (ERP) system using Airtable, along with other API-friendly applications, because the software has Product Data Management (PDM) built into it. PDM is the architecture of the data storage system which, in a nutshell, is the organization, storage, and retrieval of any data that might be tied to a manufacturing process. Since Airtable has a built-in PDM system, we are able to store all our CAM files, G-code, setup documents, tool data (where we log important data about our Helical and Harvey tools), fixture data, and any other data that needs to be tied to a step for making a part. We now have a place to bring together product data (images, instructions, inventory, links, etc), customer information (CRM data), data on sales, marketing development and deployment, a schedule, and more, all in one place. All of the integrations and automations that I built saves hours of manual work and prevents a multitude of mistakes.

Photo Courtesy of: Jeremy Taylor, Defiant CNC

What is your favorite job you have worked on?

I just finished a production run on a job where I completed 12 pieces of two different parts out of hardened 17-4 stainless from start to finish. The cycle time was just over four hours. Each part required three operations after the stock was sawed and heat treated. I designed, modeled, and made two sets of fixtures for each operation in order to load one set while the other was being machined.

When have Harvey or Helical products helped your business?

A majority of the endmills that we stock are Harvey Tool and Helical products. We utilize Fusion 360, which has a tool library full of Harvey Tool and Helical products. About a week ago, we purchased some Harvey Tool flat bottom endmills which saved substantial time on a large production run because we no longer had to circular interpolate a hole. Whenever we are in a pinch and need a tool quickly, Helical Solutions and Harvey Tool always come through.

Photo Courtesy of: Jeremy Taylor, Defiant CNC

Why is high quality tooling important to you?

High quality tools allow us to spend more time machining and less time changing tools. Our go-to tool is Helical’s 3 flute – 40-degree helix with ZPlus, whether we need 1/8 end mills or 5/8 endmills, they get the job done.

What advice do you have for others who want to try High Efficiency Milling?

Consider the material that you are cutting. Consult with your tooling vendor and/or documentation on their website to obtain a starting point and go from there. Helical Solutions has great information on their website and on their social media accounts, with regard to their products. It is worth consulting these sources when utilizing their tools.

Photo Courtesy of: Jeremy Taylor, Defiant CNC

If you could give one piece of advice to a new machinist ready to take the #PlungeIntoMachining, what would it be?

Learning needs to be continuous. Don’t just expect to learn everything that you need to know in one place. Constantly increment your skills in every aspect of machining.

Is there anything else you would like to share with the “In The Loupe” community?

I am grateful for the opportunity to talk about my experiences with Harvey Tool and Helical products and my business. I use Harvey Tool and Helical products because they work well. I will continue to document my usage of their products on my website DefiantCNC.com, as well as my company’s social media accounts (@defiantcnc on Instagram, LinkedIn, and Facebook). Be sure to check them out.

Photo Courtesy of: Jeremy Taylor, Defiant CNC

Workshops for Warriors – Featured Customer

Featured Image Courtesy of Workshops for Warriors

In 2008, Hernán Luis y Prado, a United States Navy officer, noticed his fellow service members looking for a successful path in life after service. Hernán decided he needed to make a change. He set out to make a difference for his fellow service members by starting Workshops for Warriors, a state-licensed, board governed, fully audited, nonprofit school. Its mission is to provide quality training, accredited educational programs, and opportunities for its students to earn third-party nationally recognized credentials to enable Veterans, transitioning service members, and others to be successfully trained and placed in their chosen advanced manufacturing career field.

We had the honor of speaking with Marine Veteran Scott Leoncini, an instructor at Workshops for Warriors, about the accomplishments and amazing work Workshops for Warriors does for our Veterans.

What Does Workshops for Warriors Offer for Our Veterans?

Workshops for Warriors offers two primary tracks of training, both taught by Veterans: welding and machining, Scott explained. After choosing a track, students become a part of the 16-week accelerated program. Those with only a minimum of four months and one nationally-recognized certification can walk across the shipyards and gain employment. Workshops for Warriors remains committed to providing free training to Veterans who do not have access to living-wage jobs. U.S. Veterans often face challenges as they transition to civilian life, including significant barriers to civilian employment. In addition to the hard technical skills, our students are also learning soft skills such as attitude, communication, work ethic, teamwork, time management, problem-solving, critical thinking, and conflict resolution.

A proven path into a rewarding career can eliminate problems like unemployment, homelessness, broken families, and suicide. The problem of Veteran unemployment does not have easy, short-term solutions. Workshops for Warriors is uniquely positioned to expand proven innovative techniques to give Veterans marketable employment that will allow them to build careers and families. 

How Did You Find Workshops for Warriors and Become an Instructor?

After I left the Marines in 2009, after serving two tours in Iraq as a combat engineer, I desired an action-packed career. I thought my best option was to start a career in law enforcement. I got a job at a security company and worked there for a few years. During this time, a close friend of mine tragically passed away in a helicopter crash, leaving behind his pregnant wife. This made me reevaluate my current life with my wife and two children. I decided I didn’t need that action-packed career, and that my family comes before anything.

Another friend of mine actually told me about Workshops for Warriors and how it was giving him career skills in welding, and he talked about a machining program. When I showed up, I had no idea what was in store for me. I started learning all about CNC machines, and how to program and run these things. It was eye-opening and I was having a great time. After my first semester, I was asked to become a teacher’s assistant and I’ve been teaching here now for almost five years.

Where Does Your Passion for Teaching Come From?

I love teaching Veterans and helping them transition so they don’t have to go through the same five years I did of, “What am I going to do with my life?” I’ve gone through the same situation a lot of the people coming to us are currently in.

I think that there are three fundamentals that anyone looking for a career or path can apply to their lives and be successful. You have to show up on time, you have to work hard, and you have to be willing to learn. I didn’t know anything about machinery when I first got into this field. When I went through it as a student myself, I applied those three things to my work habits, and now I’m an instructor. I had pigeonholed myself for a long time. But you have to recognize that there’s always something else, something up next and that’s what I want to help teach the Veterans who come through here.

What Courses Does Workshops for Warriors Provide?

We offer many different courses, including CAD courses in Solidworks and CAM courses in Mastercam, and we offer welding courses for Gas Metal and Flux Cored Arc Welding. We also offer advanced training in Flowmaster Programming and Waterjet Operation, 3D Printing, and Robotics. With these courses, we offer many credentials to start a real career. The machining program is accredited by the National Institute for Metalworking Skills (NIMS). NIMS is recognized by the United States Department of Education. The welding program is accredited by the American Welding Society (AWS), which is the worldwide leader in certification programs for the welding industry.

Thanks to private donors, Veterans and transitioning service members are able to become trained and certified in our advanced manufacturing programs. Students can apply to enter one of our programs, or take specific classes that meet their needs.

What Jobs Have You Seen Veterans Acquire After Workshops for Warriors?

We have seen many success stories from Veterans once they leave Workshops for Warriors. One Veteran, in particular, visited us in search of direction in 2019. The machining program had one spot left for the semester, so he took it. He is now certified in machining and welding. He entered a job market that was struggling after his graduation. But he still had a job lined up with 5th Axis Machining in San Diego. His future plans are to own his own business to support his family.

How Could People Help Support Workshops for Warriors?

They can donate directly to us on our website, or on our Facebook page. Or, people looking to help support us can reach out to us by email, [email protected], or by calling us at 619-550-1620, with any questions. We also accept equipment donations for each program, welding, and machining. You can also support us by following on Facebook, Instagram, Twitter, LinkedIn, YouTube, or our newsletter.

What Advice Would you Give to Anyone Looking to Start a Career Path?

After leaving the service, I fell into a depression. I kept thinking, “I’ll never be as good as I was back then.” It was hard to not have “Marine” be the primary part of my identity, so I became blinded by my obsession with still being the superhero kicking down doors. Don’t paint yourself into a corner. Be flexible and make sure to show up on time, work hard, and be willing to have an open mind and ready to learn. Test your comfort zone. When I left the service, I only knew how to be the man with the gun. Workshops for Warriors gave me a chance to be more than that – it gave me a direction in life. I now get to do what I love and help my fellow Veterans.

To learn more about Workshops for Warriors and their mission you can visit their website or follow them on Instagram, Facebook, LinkedIn or Twitter.

The Secret Mechanics of High Feed End Mills

A High Feed End Mill is a type of High-Efficiency Milling (HEM) tool with a specialized end profile that allows the tool to utilize chip thinning to have dramatically increased feed rates. These tools are meant to operate with an extremely low axial depth so that the cutting action takes place along the curved edge of the bottom profile. This allows for a few different phenomena to occur:

  • The low lead angle causes most of the cutting force to be transferred axially back into the spindle. This amounts to less deflection, as there is much less radial force pushing the cutter off its center axis.
  • The extended curved profile of the bottom edge causes a chip thinning effect that allows for aggressive feed rates.

The Low Lead Angle of a High Feed End Mill

As seen in Figure 1 below, when a High Feed End Mill is properly engaged in a workpiece, the low lead angle, combined with a low axial depth of cut, transfers the majority of the cutting force upward along the center axis of the tool. A low amount of radial force allows for longer reaches to be employed without the adverse effects of chatter, which will lead to tool failure. This is beneficial for applications that require a low amount of radial force, such as machining thin walls or contouring deep pockets.

high feed mill roughing
Figure 1: Isometric view of a feed mill engaged in a straight roughing pass (left), A snapshot front-facing view of this cut (right)

Feed Mills Have Aggressive Feed Rates

Figure 1 also depicts an instantaneous snapshot of the chip being formed when engaged in a proper roughing tool path. Notice how the chip (marked by diagonal lines) thins as it approaches the center axis of the tool. This is due to the curved geometry of the bottom edge. Because of this chip thinning phenomenon, the feed of the tool must be increased so that the tool is actively engaged in cutting and does not rub against the workpiece. Rubbing will increase friction, which in turn raises the level of heat around the cutting zone and causes premature tool wear. Because this tool requires an increased chip load to maintain a viable cutting edge, the tool has been given the name “High Feed Mill.”

high feed end mill ad

Other Phenomena Due to Curved Geometry of Bottom Edge

The curved geometry of the bottom edge also sanctions for the following actions to occur:

  • A programmable radius being added to a CAM tool path
  • Scallops forming during facing operations
  • Different-shaped chips created during slotting applications, compared to HEM roughing

Programmable Radius

Helical Solutions’ High Feed End Mills has a double radius bottom edge design. Because of this, the exact profile cannot be easily programmed by some CAM software. Therefore, a theoretical radius is used to allow for easy integration.  Simply program a bullnose tool path and use the theoretical radius (seen below in Figure 2) from the dimensions table as the corner radius.

high feed mill programmable radius
Figure 2: Programmable radius of a double radius profile tool

Managing Scallops

A scallop is a cusp of material left behind by cutting tools with curved profiles. Three major factors that determine the height and width of scallops are:

  1. Axial Depth of Cut
  2. Radial Depth of Cut
  3. Curvature of Bottom Edge or Lead Angle

Figure 3 below is a depiction of the scallop profile of a typical roughing cut with a 65% radial step over and 4% axial depth of cut. The shaded region represents the scallop that is left behind after 2 roughing passes and runs parallel to the tool path.

roughing cut scallop profile
Figure 3: Back view of roughing cut with a 65% radial step over

Figures 4 and 5 show the effects of radial and axial depth of cuts on the height and width of scallops. These figures should be viewed in the context of Figure 3. Percentage by diameter is used rather than standard units of measurement to show that this effect can be predicted at any tool size. Figure 4 shows that a scallop begins to form when the tool is programmed to have a radial step over between 35% and 40%. The height increases exponentially until it is maximized at the axial depth of cut. Figure 5 shows that there is a linear relationship between the radial step over and scallop width. No relationship is seen between scallop width and axial depth of cut as long as ADOC and the radius of curvature of the bottom cutting edge remains consistent.

graph of scallop height versus depth of cut
Figure 4: Graph of Scallop Height vs. Depth of Cut
graph of scallop width versus depth of cut
Figure 5: Scallop Width vs. Depth of Cut

From the graphs in Figures 4 and 5 we get the following equations for scallop dimensions.

Notes regarding these equations:

  • These equations are only applicable for Helical Solutions High Feed End Mills
  • These equations are approximations
  • Scallop height equation is inaccurate after the axial depth of cut is reached
  • RDOC is in terms of diameter percentage (.55 x Diameter, .65 x Diameter, etc…)

Shop Helical Solutions’ Fully Stock Selection of High Feed End Mills

Curvature of the Bottom Edge of High Feed End Mills

The smaller the radius of curvature, the larger the height of the scallop. For example, the large partial radius of the Helical Solutions High Feed End Mill bottom cutting edge will leave a smaller scallop when compared to a ball end mill programmed with the same tool path. Figure 6 shows a side by side comparison of a ball end mill and high feed mill with the same radial and axial depth of cut. The scallop width and height are noticeably greater for the ball end mill because it has a smaller radius of curvature.

feed mill versus ball end mill
Figure 6: Scallop diagram of High Feed Mill and Ball End Mill with the same workpiece engagement

Full Slotting

When slotting, the feed rate should be greatly reduced relative to roughing as a greater portion of the bottom cutting edge is engaged. As shown in Figure 7, the axial step down does not equate to the axial engagement. Once engaged in a full slot, the chip becomes a complex shape. When viewing the chip from the side, you can see that the tool is not cutting the entirety of the axial engagement at one point in time. The chip follows the contour on the slot cut in the form of the bottom edge of the tool. Because of this phenomenon, the chip dips down to the lowest point of the slot and then back up to the highest point of axial engagement along the side. This creates a long thin chip that can clog up the small flute valleys of the tool, leading to premature tool failure. This can be solved by decreasing the feed rate and increasing the amount of coolant used in the operation.

high feed mill chip formation
Figure 7: Formation of a chip when a feed mill is engaged in a full slotting operation.

In summary, the curved profile of the bottom edge of the tool allows for higher feed rates when high feed milling, because of the chipping thinning effect it creates with its low lead angle. This low lead angle also distributes cutting forces axially rather than radially, reducing the amount of chatter that a normal end mill might experience under the same conditions. Machinists must be careful though as the curved bottom edge also allows for the formation of scallops, requires a programmable radius when using some CAM packages, and make slotting not nearly as productive as roughing operations.

Harvey Performance Company Opens New 79,000-Square-Foot Manufacturing Plant in Gorham

GORHAM, ME (October 13, 2020) – Harvey Performance Company, the parent company of the Harvey Tool, Helical Solutions, and Micro 100 industrial cutting tool brands, last month opened the doors to a new, 79,000-square-foot, state-of-the-art manufacturing facility in Gorham, Maine, to support the tremendous growth and product demand its brands continue to experience.

Harvey Performance Company was quickly outgrowing its Sanford Drive facility in Gorham, Maine, where Helical Solutions products have been manufactured for more than 15 years. The new manufacturing facility, which is just 5 minutes away on Raceway Drive, will become home to Helical Solutions product manufacturing and will serve as an innovation hub for all Harvey Performance Company brands.

“We couldn’t be more excited about this new facility,” said Harvey Performance Company Senior Vice President of Sales Jerry Gleisner. “We’re quite literally opening the doors to countless opportunities for us to serve our customers in ways unmatched in the industry.”

“This new facility is an exciting step for our business, as this investment will create opportunities for us to continue to grow,” said Harvey Performance Company Vice President of Operations Steve Vatcher. “In light of the COVID-19 Pandemic, we worked closely with state and local officials to ensure that the completion of our new facility was done in a way that prioritized the health and safety of all involved. I couldn’t be more proud of how everyone came together to make this facility a reality during these unprecedented times.

“When it is safe to do so, we look forward to hosting the Gorham community, our neighbors for more than 15 years, at our new home for a ribbon cutting ceremony to share this exciting milestone with us.”

Harvey Performance Company’s New Manufacturing Plant Will:

  • Expand upon its current research and development capabilities to design, test, and manufacture innovative and high performing cutting tools.
  • Accelerate Harvey Performance Company’s new product growth while maintaining its in-stock status and same-day shipping options for all catalog standard items.
  • Host its distributor partners and customers in a state-of-the-art setting that showcases its capabilities.
  • Meet the needs of the market by scaling the size of Harvey Performance Company’s business in the future, through added machines and personnel.
  • Attract, recruit, and retain high-quality employees, engineers, and operators with a high-class work environment.

Schon DSGN – Featured Customer

Featured Image Courtesy of Ian Schon, Schon DSGN

In 2012, engineer Ian Schon wanted to put his skill for design to the test. He decided to challenge himself by designing a normal, everyday item: a pen. His goal was to take the pen from the design concept to manufacturing it within his own shop. Ian designed his pen how he thought a pen should be: durable, reliable, compact, leak-proof, and easy to use. Most of all, though, he wanted the pen to be of a superior quality, not something easily lost or thrown away.

With the design concept in place, Ian started his work on engineering and manufacturing his new pen. He made many prototypes, and with each discovered new features and additions to better his design. Today, Ian manufacturers his pens through local fabrications in Massachusetts, using local supplies. He makes them from 6061 Aluminum, unique in that it molds to its users’ hand, over time. His pens are designed to outlast its user and be passed on through generations.

Ian was kind enough to take time out of his busy schedule to answer some questions about his manufacturing success.

Schon DSGN silver wrist watch with black band
Photo Courtesy of: Ian Schon, Schon DSGN

What sets Schon DSGN apart from competition?

I think I have a unique approach to designing and manufacturing. I design things that I like, and make them the way that I want to.  I don’t rush things out the door. I’m not thinking about scale, growth, making a big shop, etc. I just want to live a simple life where I make cool objects, sell them, and have enough time in the week to sneak out into the woods and ride my bike. This ethos takes the pressure off a lot, and that makes the workflow freer without as much stress as I had in my past career as a product development engineer.

This workflow isn’t for everyone. it’s not a winning combo for massive business success, per se, and if you audited me you would tell me I’m holding back by not scaling and hiring, but I like it. I see myself as a hybrid between artist and entrepreneur. I love doing things start to finish, blank paper to finished part on the machine. Owning that entire workflow allows for harmony of engineering, machining, tooling, finishing, R+D, marketing, etc. Further, it ensures that I don’t miss critical inflection points in the process that are ripe for process evolution and innovation, resulting in a better product in the end.

I’m sure the way I do things will change over time, but for now I’m still figuring things out and since I work largely alone (I have one amazing helper right now assisting with assembly, finishing, and shipping) I have lots of flexibility to change things and not get stuck in my ways.

Also, by working alone, I control the music. Key!

schon dsgn turning metal on lathe
Photo Courtesy of: Ian Schon, Schon DSGN

Where did your passion for pens come from?

My friend Mike had a cool pen he got from a local shop and I was like “man I like that,” so I made one with some “improvements.” At the time, in my mind, they were improvements, but I have learned now that they were preferences, really. I made a crappy pen on a lathe at the MIT MITERS shop back in 2010, and that summer I bought a Clausing lathe on craigslist for $300 and some tooling and started figuring it all out. I made a bunch of pens, wrote with them, kept evolving them, and eventually people asked me to make pens for them.  I didn’t really intend to start a business or anything, I just wanted to make cool stuff and use it. Bottle openers, knives, bike frames, etc. I made lots of stuff. Pens just stuck with me and I kept pushing on it as a project for my design portfolio. Eventually it became something bigger. Turns out my pen preferences were shared with other people.

Schon dsgn gold and copper metal pens
Photo Courtesy of: Ian Schon, Schon DSGN

What is the most difficult product you have had to make and why?

Making watch cases – wow. What an awful part to try and make on a desktop Taig 3 axis mill and a Hardinge lathe in my apartment! I started working on machining watch cases in 2012, and I finished my first one in my apartment in 2015 (to be fair, I was working on lots of other stuff during that time! But yeah, years…). What a journey. Taught me a lot. Biting off more than you can chew is a great way to learn something. 

What is the most interesting product you’ve made?

When I worked at Essential Design in Boston I worked on the front end of a Mass Spectrometer. The requirements on the device were wild. We had high voltage, chemical resistance, crazy tolerances, mechanism design, machining, injection molding – truly a little bit of everything! It was a fun challenge that I was fortunate to be a part of. Biomolecule nanoscale analysis device. Try saying that ten times fast.

I have something fountain pen related in the works now that I find more interesting, and very, very complex, but it’s under wraps a bit longer. Stay tuned. 

Schon dsgn gold and copper metal pens
Photo Courtesy of: Ian Schon, Schon DSGN

Who is the most famous contact that you have worked on a project with?

I have made watches for some incredible customers, but I unfortunately cannot talk about who they are. Most of my watch work outside of my own parts is also under NDA which is a bummer, but hey it was great work regardless.

Same thing with the pens. I know that some of my pen are in the touring cases of a few musicians, one of which is in the rock and roll hall of fame. But I have to keep it tight!

Before leaving to work for myself, I was part of a design team at IDEO in Cambridge that designed the new Simplisafe Home Security System. As an engineer and designer, I got listed on the patents. That wasn’t machining and was more design and engineering of injection molded plastic assemblies,  but it was still cool, though! Cutting my teeth in the design industry before machining helps me a lot with the creative process in the workshop. Lots of overlap.

What capabilities does your shop have?

I utilize Citizen L series sliding headstock machines to run my company. These are Swiss Machines (though made in Japan) with twin spindles and have live tooling for milling operations. I got into this type of machining after getting advice from friends in the industry and subcontracting my work to shops with these style of machines for 7 years.

Beyond the Swiss Machines, I have a new Precision Matthews Manual Mill, a Southbend Model A, a Hardinge Cataract Lathe, and a bunch of smaller Derbyshire lathes and mills. Most of these are for maintenance related tasks – quick mods and fixtures and my watchmaking/R&D stuff. I also have a Bantam Tools Desktop CNC machine on the way, a nice machine for quick milled fixtures in aluminum and nonferrous materials. I tested this machine during their development phases and was really impressed.

What CAM/CAD software are you using?

I use Fusion 360 for quick milled stuff, but most of my parts are programmed by hand since the lathe programming for Swiss work can be done without much CAM. I’m sure I could be doing things better on the programming side, but hey, every day I learn something new. Who knows what I’ll be doing a year or two from now?

schon dsgn turning wrist watch on lathe
Photo Courtesy of: Ian Schon, Schon DSGN

What is your favorite material to work with and why?

Brass and Copper. The chips aren’t stringy, it’s easy to cut quickly and the parts have this nice hefty feel to them. Since I make pens, the weight is a big piece of the feeling of a pen. The only downside is I’m constantly figuring out ways to not dent the parts as they are coming off the machines! My brass parts are like tiny brass mallets and they LOVE to get dinged up in the ejection cycles. I ended up making custom parts catchers and modifying the chutes on the machines to navigate this. I might have some conveyors in my future….yeah. Too many projects!

schon dsgn disassembled wrist watch
Photo Courtesy of: Ian Schon, Schon DSGN

Why is high quality tool performance important to you?

It’s not just important, it’s SUPER important. As a solo machinist running my own machines, being able to call a tooling company and get answers on how I should run a tool, adjust its RPM, feed, DOC, or cutting strategy to get a better result is invaluable. I find that as much as I’m paying for tool performance, I’m also paying for expertise, wisdom and answers. Knowing everything is cool and all (and I know some of you out there know everything under the sun), but since I don’t know everything, it’s so nice to be able to pick up a phone and have someone in my corner. These tech support people are so crucial. Being humble and letting support guide me through my tooling challenges has helped me grow a lot. It’s like having a staff of experienced machinists working at my company, for free! Can’t beat that. Micro 100 and Helical have helped me tons with their great support.

schon dsgn multicolored fountain pens
Photo Courtesy of: Ian Schon, Schon DSGN

When was a time that Harvey, Helical or Micro product really came through and helped your business?

The Helical team (shout out to Dalton) helped me nail some machining on some very wild faceted pens I was working on this month. When I switched to Helical, my finishes got crazy good. I just listened to recommendations, bought a bunch of stuff, and kept trying what Dalton told me to. Eventually, that led to a good recipe and manageable tool wear. It was great!

I also like how representatives from the Harvey/Helical/Micro family often cross reference each other and help me find the right solution, regardless of which company I’m getting it from. Nice system.

The quiet hero in my shop is my Micro 100 quick change system. It just works great. Fast to swap tools, easy to setup, cannot argue with it! Too good. 

Schon DSGN silver wrist watch with black band
Photo Courtesy of: Ian Schon, Schon DSGN

If you could give one piece of advice to a new machinist ready to take the #PlungeIntoMachining, what would it be?

Find a mentor who supports you and challenges you. Find a good tooling company, or good tooling companies, and make good relationships with their tech support so you can get answers. Make good relationships with service technicians who can help you fix your machines. Be a good person. Don’t let yourself become a hot head under the pressure of this industry (since it can be hard at times!), cooler heads prevail, always. Be open to seeing things from other viewpoints (in life and in machining), don’t be afraid to flip a part around and start over from square one.

To learn more about Ian and Schon DSGN, follow them @schon_dsgn and @the_schon on Instagram and check out his website. And, to learn more about how Ian got his start in the manufacturing industry, check out this video.

Rennscot LLC – Featured Customer

Featured Image Courtesy of David Bamforth, Rennscot LLC

David Bamforth is the founder and CEO of Rennscot LLC, a manufacturing company based out of Woburn, Massachusetts, which was created to meet product design demands of both individual and commercial clients. From idea to prototype, and eventually to final product, Rennscot LLC prides itself on its ability to make part ideas come to life. David took some time to talk with us about Rennscot LLC, his company’s machining capabilities, and much more.

Assortment of end mills and tool holders at Rennscott LLC
Photo Courtesy of: David Bamforth, Rennscot LLC

What capabilities does your shop have?

We are mostly a mill shop with two verticals and one 5-axis machine. We also have a small bar fed lathe, a larger sub-spindle live-tooling lathe, and some design tools like a Faro Design Scan Arm. We work predominantly with aluminum, but sometimes see brass, stainless, titanium, and steel alloy jobs come through. We use Fusion 360 for everything and currently all 4 of our machines are Haas.

What sets Rennscot LLC apart from the competition?

We are a bit different from most shops because, in addition to machining services, we also offer design services. A lot of our jobs are won because we are a one-stop-shop from idea to producing the final product. Recently we have been making a lot of parts for vehicle restoration. Typically, we are just handed a part and asked to reproduce it.

What is your favorite part of the job?

Problem solving and learning new skills. We are a pretty young team and love being challenged by new projects. We also pride ourselves on being pretty innovative with our machining strategies to help reduce lead times and cost for our customers.

cnc machined metal part from Rennscot LLC
Photo Courtesy of: David Bamforth, Rennscot LLC

Where did your passion for automobiles come from?

Like many, I have always been passionate about cars. I have some great memories of going to car shows with my dad and watching any TV show with a car in it as a kid. Nowadays, I spend my personal time taking our shop development car, a Porsche Cayman, to the track.

What is the coolest product you have made?

We have had some pretty unusual characters bring us some really cool projects. Currently, we are working with a guy from Connecticut on laser scanning a model Mercedes C10 Le Mans car that we will CAD model, so a full-sized car body can be reproduced. It’s a really interesting project, trying to take a 1:43 car and blow it up to full size. Eventually, we will help design and manufacture many of the machined components on this car. Also, we once made a custom billet alternator mount in just 5 days for a 996 Porsche GT3 with a Chevy LS engine in it. We really enjoyed being part of that project and the V8 sounded amazing on track!

cnc machined metal part from Rennscot LLC
Photo Courtesy of: David Bamforth, Rennscot LLC

What is the most difficult product you have made?

We once worked on an enclosure for a handheld x-ray machine. The part was only about 1”x 1.25” x4” and only had .040” walls all around. The main pocket was machined with our go-to Helical ¼” reduced shank end mill. It also had #0-80 taps all along the top edge of the enclosure, making for a few broken taps! It was a pain to get dialed in but once the process was proved out it was really rewarding to get consistent good parts off the will.

Why is high quality tool performance important to you?

Once we started using high quality end mills, we immediately saw an improvement in tool life and surface finish. We also really enjoy using tools that are backed by a company that puts out so much information and resources to help its customers out.

When was a time that Harvey Tool or Helical products really came through and helped your business?

We have had several moments when we hit a wall while building a process for a new part, and Helical’s phone support helped us find the perfect tool for the process. The combination of great phone support, having such a vast array of product offerings, and all of the tools always being in stock has helped my business tremendously.

Rennscot LLC machine shop assortment of harvey tool and helical end mills
Photo Courtesy of: David Bamforth, Rennscot LLC

Are you guys using High Efficiency Milling (HEM) techniques to improve cycle times?

Always! All our mills are spec’ed with HSM and 12k RPM spindles, and we take full advantage of this with chip breaking roughers. Honestly, we are so young that we have only ever used HEM techniques, so I’m honestly just confused by companies that don’t use it. Not using HEM is like not driving a car on the highway because it’s too fast.

If you could give one piece of advice to a new machinist ready to take the #PlungeIntoMachining, what would it be?

Machining is probably the most in demand and most satisfying industries that someone can get into now-a-days. There are a lot of companies that are in demand for green machinists who are just eager to learn. I would recommend putting together and sending out a resume to local shops that shows that you have the ability to take on projects and complete them.

If anyone is interested in learning more about what we do our manufacturing website, rennscotmfg.com is a great resource. Also, check us our on Instagram at @rennscot.

How to Optimize Results While Machining With Miniature End Mills

 The machining industry generally considers micromachining and miniature end mills to be any end mill with a diameter under 1/8 of an inch. This is also often the point where tolerances must be held to a tighter window. Because the diameter of a tool is directly related to the strength of a tool, miniature end mills are considerably weaker than their larger counterparts, and therefore, lack of strength must be accounted for when micromachining. If you are using these tools in a repetitive application, then optimization of this process is key.

Size Comparison for Harvey Tool’s #13901 Square Miniature End Mill

Key Cutting Differences Between Conventional and Miniature End Mills

Runout

Runout during an operation has a much greater effect on miniature tools, as even a very small amount can have a large impact on the tool engagement and cutting forces. Runout causes the cutting forces to increase due to the uneven engagement of the flutes, prompting some flutes to wear faster than others in conventional tools, and breakage in miniature tools. Tool vibration also impacts the tool life, as the intermittent impacts can cause the tool to chip or, in the case of miniature tools, break. It is extremely important to check the runout of a setup before starting an operation. The example below demonstrates how much of a difference .001” of runout is between a .500” diameter tool and a .031” diameter tool.

chart comparing tool diameter for runout in micromachining with miniature end mills
The runout of an operation should not exceed 2% of the tool diameter. Excess runout will lead to a poor surface finish.

Chip Thickness

The ratio between the chip thickness and the edge radius (the edge prep) is much smaller for miniature tools. This phenomena is sometimes called “the size effect” and often leads to an error in the prediction of cutting forces. When the chip thickness-to-edge radius ratio is smaller, the cutter will be more or less ploughing the material rather than shearing it. This ploughing effect is essentially due to the negative rake angle created by the edge radius when cutting a chip with a small thickness.

If this thickness is less than a certain value (this value depends of the tool being used), the material will squeeze underneath the tool. Once the tool passes and there is no chip formation, part of the plowed material recovers elastically. This elastic recovery causes there to be higher cutting forces and friction due to the increased contact area between the tool and the workpiece. These two factors ultimately lead to a greater amount of tool wear and surface roughness.

chart of edge radius in relation to chip thickness for micromachining
Figure 1: (A) Miniature tool operation where the edge radius is greater than the chip thickness (B) Conventional operation where the edge radius is small than the chip thickness

Tool Deflection in Conventional vs. Micromachining Applications

Tool deflection has a much greater impact on the formation of chips and accuracy of the operation in micromachining operations, when compared to conventional operations. Cutting forces concentrated on the side of the tool cause it to bend in the direction opposite the feed. The magnitude of this deflection depends upon the rigidity of the tool and its distance extended from the spindle. Small diameter tools are inherently less stiff compared to larger diameter tools because they have much less material holding them in place during the operation. In theory, doubling the length sticking out of the holder will result in 8 times more deflection. Doubling the diameter of an end mill it will result in 16 times less deflection. If a miniature cutting tool breaks on the first pass, it is most likely due to the deflection force overcoming the strength of the carbide. Here are some ways you can minimize tool deflection.

Workpiece Homogeny

Workpiece homogeny becomes a questionable factor with decreasing tool diameter. This means that a material may not have uniform properties at an exceptionally small scale due to a number of factors, such as container surfaces, insoluble impurities, grain boundaries, and dislocations. This assumption is generally saved for tools that have a cutter diameter below .020”, as the cutting system needs to be extremely small in order for the homogeny of the microstructure of the material to be called into question.

Surface Finish

Micromachining may result in an increased amount of burrs and surface roughness when compared to conventional machining. In milling, burring increases as feed increases, and decreases as speed increases. During a machining operation, chips are created by the compression and shearing of the workpiece material along the primary shear zone. This shear zone can be seen in Figure 2 below. As stated before, the chip thickness-to-edge radius ratio is much higher in miniature applications. Therefore, plastic and elastic deformation zones are created during cutting and are located adjacent to the primary shear zone (Figure 2a). Consequently, when the cutting edge is close to the border of the workpiece, the elastic zone also reaches this border (Figure 2b). Plastic deformation spreads into this area as the cutting edge advances, and more plastic deformation forms at the border due to the connecting elastic deformation zones (Figure 2c). A permanent burr begins to form when the plastic deformation zones connect (Figure 2d) and are expanded once a chip cracks along the slip line (Figure 2e). When the chips finally break off from the edge of the workpiece, a burr is left behind (Figure 2f).

burr formation mechanism using a miniature end mill
Figure 2: Burr formation mechanism using a miniature end mill 

Tool Path Best Practices for Miniature End Mills

Because of the fragility of miniature tools, the tool path must be programmed in such a way as to avoid a sudden amount of cutting force, as well as permit the distribution of cutting forces along multiple axes. For these reasons, the following practices should be considered when writing a program for a miniature tool path:

Ramping Into a Part

Circular ramping is the best practice for moving down axially into a part, as it evenly distributes cutting forces along the x, y, and z planes. If you have to move into a part radially at a certain depth of cut, consider an arching tool path as this gradually loads cutting forces onto the tool instead of all at once.

Micromachining in Circular Paths

You should not use the same speeds and feed for a circular path as you would for a linear path. This is because of an effect called compounded angular velocity. Each tooth on a cutting tool has its own angular velocity when it is active in the spindle. When a circular tool path is used, another angular velocity component is added to the system and, therefore, the teeth on the outer portion of tool path are traveling at a substantially different speed than expected. The feed of the tool must be adjusted depending on whether it is an internal or external circular operation. To find out how to adjust your feed, check out this article on running in circles.

Slotting with a Miniature End Mill

Do not approach a miniature slot the same way as you would a larger slot. With a miniature slot, you want as many flutes on the tool as possible, as this increases the rigidity of the tool through a larger core. This decreases the possibility of the tool breaking due to deflection. Because there is less room for chips to evacuate with a higher number of flutes, the axial engagement must be decreased. With larger diameter tools you may be stepping down 50% – 100% of the tool diameter. But when using miniature end mills with a higher flute count, only step down between 5% – 15%, depending on the size of the diameter and risk of deflection. The feed rate should be increased to compensate for the decreased axial engagement. The feed can be increased even high when using a ball nose end mill as chip thinning occurs at these light depths of cut and begins to act like a high feed mill.

Slowing Down Your Feed Around Corners

Corners of a part create an additional amount of cutting forces as more of the tool becomes engaged with the part. For this reason it is beneficial to slow down your feed when machining around corners to gradually introduce the tool to these forces.

Climb Milling vs. Conventional Milling in Micromachining Applications

This is somewhat of a tricky question to answer when it comes to micromachining. Climb milling should be utilized whenever a quality surface finish is called for on the part print. This type of tool path ultimately leads to more predictable/lower cutting forces and therefore higher quality surface finish. In climb milling, the cutter engages the maximum chip thickness at the beginning of the cut, giving it a tendency to push away from the workpiece. This can potentially cause chatter issues if the setup does not have enough rigidity.  In conventional milling, as the cutter rotates back into the cut it pulls itself into the material and increases cutting forces. Conventional milling should be utilized for parts with long thin walls as well as delicate operations.

Combined Roughing and Finishing Operations

These operations should be considered when micromachining tall thin walled parts as in some cases there is not sufficient support for the part for a finishing pass.

Helpful Tips for Achieving Successful Micromachining Operations With Miniature End Mills

Try to minimize runout and deflection as much as possible when micromachining with miniature end mills. This can be achieved by using a shrink-fit or press-fit tool holder. Maximize the amount of shank contact with the collet while minimizing the amount of stick-out during an operation. Double check your print and make sure that you have the largest possible end mill because bigger tools mean less deflection.

  • Choose an appropriate depth of cut so that the chip thickness to edge radius ratio is not too small as this will cause a ploughing effect.
  • If possible, test the hardness of the workpiece before machining to confirm the mechanical properties of the material advertised by the vender. This gives the operator an idea of the quality of the material.
  • Use a coated tool if possible when working in ferrous materials due to the excess amount of heat that is generated when machining these types of metals. Tool coatings can increase tool life between 30%-200% and allows for higher speeds, which is key in micro-machining.
  • Consider using a support material to control the advent of burrs during a micromachining application. The support material is deposited on the workpiece surface to provide auxiliary support force as well as increase the stiffness of the original edge of the workpiece. During the operation, the support material burrs and is plastically deformed rather than the workpiece.
  • Use flood coolant to lower cutting forces and a greater surface finish.
  • Scrutinize the tool path that is to be applied as a few adjustments can go a long way in extending the life of a miniature tool.
  • Double-check tool geometry to make sure it is appropriate for the material you are machining. When available, use variable pitch and variable helix tools as this will reduce harmonics at the exceptionally high RPMs that miniature tools are typically run at.
variable pitch versus non-variable pitch
Figure 3: Variable pitch tool (yellow) vs. a non-variable pitch tool (black)

Titan Ring Design – Featured Customer

Featured Image Courtesy of Trevor Hirschi, Titan Ring Design

Officially started in 2015, Titan Ring Design is a high quality machine shop that designs rings, as well as mechanical tie clips, art based designs, and freelance custom designs. While working at a machine shop that produced top notch parts for just about every type of field you can imagine, now owner of Titan Ring Design, Trevor Hirschi, noticed that the machining industry is mostly about cranking out a mass quantity of the highest quality parts as quickly as possible. This often resulted in compromised tolerances and part finishes, something Trevor aimed to change. Quality always comes first in his projects.

Whether you are looking for a band for an upcoming wedding, looking to replace or upgrade your current wedding ring, or just want something unique and beautiful, Trevor’s designs are different than anything else. Trevor was able to take the time and answer some questions for us about his business, machining techniques, tooling, and a lot more.

machined metal ring from Titan Ring Design
Photo Courtesy of: Trevor Hirschi, Titan Ring Design

How was Titan Ring Design started?

Titan Ring Designs is a part time, passion/hobby business of mine that I sort of started at the time I was ring shopping for a wedding ring back in 2013. I didn’t like what was available on the market and was inspired by a former Oakley designer to machine my own. I had been introduced to machining in High School at a technical college and had been working as a machinist since graduating in 2007, so I decided to make my own wedding ring. It sort of snowballed into my business in 2015, after finally deciding to make it official with a business license and some sales. Some further work experience in California for McWhinney Designs brought me greater motivation and encouragement to keep going and helped me get to where I am today. I now offer several different CNC Milled [wedding] rings, as well as a mechanical tie clip, some occasional art based designs, and freelance custom design and mill work. I also teach machining full time  at the same tech college I graduated from in my own education and enjoy sharing my knowledge and love for machining with those interested in the career.

machined propeller art from Titan Ring Design
Photo Courtesy of: Trevor Hirschi, Titan Ring Design

What capabilities does your shop have?

Custom Design in CAD/CAM, 3axis CNC Mill work, Small Scale Lathe Work, Tumbling, Finishing, Assembling, 3D Printing/Rapid Prototyping. I cut 6-4 Titanium primarily, but also work with Stainless Steel for fasteners, Aluminum and some Steel for fixtures, and Polycarbonate for prototyping ideas. I teach machining technology full time, so I have access to SolidWorks, MasterCam, Fusion360, and NC Simul. We currently have a Haas OfficeMill 3axis, Levin High Precision Instrument Maker’s Lathe, Prusa i3 MK2S 3D Printer in the shop.

What sets Titan Ring Design apart from the competition?

There are lots of people making interesting rings today, but most are done on lathes. Anyone can make a round part on a lathe. Very few of them make rings on a mill, and I feel that gives the opportunity to be creative and allows you to think outside the box more. I try to stand out in that field by offering something that makes you think about the value of the design process more by interrupting and challenging the norm. I also like to take on work that is outside of jewelry, but still highly design related. Most other ring makers stick with just rings.

Titan Ring Design machining facility
Photo Courtesy of: Trevor Hirschi, Titan Ring Design

What is your favorite part of the job and what other passions do you have?

Making cool stuff! Most machinists only end up making whatever comes through the shop, which can be cool, but most of the time you have no idea what you’re making, just some part for Customer X, Y, or Z. Being a small, design centered business, I get to come up with ideas for what to make next, and most of the time I start out making something that wasn’t ever intended to be marketed, it was simply something I wanted for myself that I found others were interested in too. I discovered machining in high school and fell in love with it when I started making parts for my dirt bikes and truck. I’ve been hooked ever since but I do have other passions. I’ve always had a big interest in LED lighting and flashlights. I’m perpetually working on different ideas for making one of my own, which will happen eventually. I’m also a bit of a health-nut and enjoy being outdoors and spending time with my family.

Who is the most famous contact that you have worked on a project with?

I made a ring for an NFL player once, but I don’t follow football and his name didn’t stick out to me so I’ve forgotten who he was. I also had the privilege of working for McWhinney Designs and made some truly remarkable products in the openable wedding ring niche market. I gained more skill in design, machining, craftsmanship, and engineering while working for Jeff McWhinney. We’re good friends and often work together to help each other when one of us gets stumped on something.

machined metal art from Titan Ring Design
Photo Courtesy of: Trevor Hirschi, Titan Ring Design

What is the most difficult project you have worked on?

I was commissioned to design from the ground up and machine was a custom set of all-titanium cabinet door handle pulls for a very high end wine cabinet. Each handle was an assembly of 32 pieces, all machined from billet 6-4 Titanium. They required over 400 individual CAM toolpath operations, 35 unique machine setups, and well over 300 hours to complete, including finishing and assembly. More than anything, it was extremely time intensive in programming, set up, and machine time. The design was a fair bit challenging in my mind and initial modeling, but didn’t compete with what it took to actually produce them. I grossly underestimated and underbid the job. But in the end, I really enjoyed making a truly one of a kind, Tour-De-Force product, even if it was completely overkill for its purpose. I enjoy making that kind of stuff, and the lessons you learn from it.

What is your favorite project you have worked on?

It’s really simple and was initially designed just because I wanted it for myself, but I have a mechanical titanium tie clip that I really enjoy making. It’s quite unique in that, as far as I know, to this day, it is the only CNC machined mechanical titanium tie clip you’ll find anywhere in the world. It puts a little bling in your formal attire, for those times you have to go full suit and tie.

machined metal band from Titan Ring Design
Photo Courtesy of: Trevor Hirschi, Titan Ring Design

Why is high quality tool performance important to you?

Because I cut mostly titanium, tools wear out quickly if you don’t have a rigid set up, the right coolant, proper feeds & speeds, and of course, high quality tooling. Harvey Tool makes such a wide variety of micro tooling that works so well in the industry of making small titanium parts, where I like to fit into. I’ve used a fair spread across Harvey’s offering and have always been impressed with performance and the feeds and speeds guides are top notch too. I had an application that required a .0035” internal corner radius which landed me with a .007” end mill. It’s still hard to comprehend tooling in this league. My machine actually recommends only tooling under 1/4” shank size, so I don’t get into Helical’s range too often. But I’ve used Helical 1/2” end mills extensively at other job shops and they are definitely made for eating metal. I was using another tool brand’s key cutters for some undercut hinges and would wear through them much more often than I thought was reasonable. When I finally decided to try Harvey’s key cutters, I was blown away with how much longer they have lasted me. Truly a game changer!

harvey tool end mills with Titan Ring Design machined tie clip
Photo Courtesy of: Trevor Hirschi, Titan Ring Design

If you could give one piece of advice to a new machinist ready to take the #PlungeIntoMachining, what would it be?

Be creative. Machining is such a rewarding career that has limitless possibilities of what you can achieve. Follow your passion and have fun with it! If you end up in a dead end shop doing something you don’t like, go somewhere else. There are so many shops that need help right now and chances are good that you can find a better shop that suits your style.

Is there anything else you would like to share with the In The Loupe community?

To those machine shops out in industry, do whatever you can to be supportive of your local trade schools that are teaching the upcoming machinist workforce. They really need your support and in turn will bring you the employees you depend on.

Please take the time to check out Titan Ring Designs website or follow them on Instagram @titanringdesigns

New Dublin Ship Fittings – Featured Customer

Featured Image Courtesy of Lucas Gilbert, New Dublin Ship Fittings

New Dublin Ship Fittings was established in 2017 by Lucas Gilbert, and is located on the scenic south shore of Nova Scotia, Canada.  Lucas began his career with a formal education in machining and mechanical engineering. In the early 2000’s, Lucas got into the traditional shipbuilding industry made famous in the region he grew up in, Lunenburg County, Nova Scotia. It is then when Lucas identified the need for quality marine hardware and began making fittings in his free time. After some time, Lucas was able to start New Dublin Ship Fittings and pursue his lifelong dream of opening a machine shop and producing custom yacht hardware.

Lucas was our grand prize winner in the #MadeWithMicro100 Video Contest! He received the $1,000 Amazon gift card, a Micro-Quik™ Quick Change System with some tooling, and a chance to be In the Loupe’s Featured Customer for February. Lucas was able to take some time out of his busy schedule to discuss his shop, how he got started in machining, and the unique products he manufactures.

How did you start New Dublin Ship Fittings?

I went to school for machine shop and then mechanical engineering, only to end up working as a boat builder for 15 years. It was during my time as a boat builder that I started making hardware in my free time for projects we were working on. Eventually, that grew into full-time work. Right now, we manufacture custom silicon bronze and stainless fittings only. Eventually, we will move into a bronze hardware product line.

New Dublin Ship Fittings shop

Photo Courtesy of: New Dublin Ship Fittings

Where did your passion for marine hardware come from?

I’ve always loved metalworking. I grew up playing in my father’s knife shop, so when I got into wooden boats, it was only a matter of time before I started making small bits of hardware. Before hardware, I would play around making woodworking tools such as chisels, hand planes, spokeshaves, etc.

What can be found in your shop?

The shop has a 13”x 30” and 16”x 60” manual lathe, a Bridgeport Milling Machine, Burgmaster Turret Drill Press, Gang Drill, Bandsaw, 30-ton hydraulic press, #2 Hossfeld Bender, GTAW, and GMAW Welding Machines, as well as a full foundry set up with 90 pounds of bronze pour capacity. We generally only work in 655 silicon bronze and 316 stainless steel.

cnc machined boat parts

Photo Courtesy of: New Dublin Ship Fittings

What projects have you worked on at New Dublin Ship Fittings that stand out to you?

I’ve been lucky to work on several amazing projects over the years. Two that stand out are a 48’ Motorsailer Ketch built by Tern Boatworks, as well as the 63’ Fusion Schooner Farfarer, built by Covey Island Boatworks. Both boats we built most of the bronze deck hardware for.

cnc milled boat cleat

Photo Courtesy of: New Dublin Ship Fittings

I’ve made many interesting fittings over the years. I prefer to work with bronze, so I generally have the most fun working on those. I’m generally the most interested when the part is very
challenging to make and custom work parts are often very challenging. I’m asked to build or machine a component that was originally built in a factory and is difficult to reproduce with limited machinery and tooling, but I enjoy figuring out how to make it work.

Why is high-quality tooling important to you?

When I first started I would buy cheaper tooling to “get by” but the longer I did it, the more I realized that cheaper tooling doesn’t pay off. If you want to do quality work in a timely fashion, you need to invest in good tooling.

What Micro 100 Tools are you currently using?

Currently, we just have the Micro 100 brazed on tooling but we have been trying to move more into inserts so we are going to try out Micro’s indexable tooling line. After receiving the Micro-Quik™ Quick Change System, we are looking forward to trying out more of what (Micro 100) has to offer. This new system should help us reduce tool change time, saving us some money in the long run.

cnc machined rigging

Photo Courtesy of: New Dublin Ship Fittings

What makes New Dublin Ship Fittings stand out from the competition?

I think the real value I can offer boat builders and owners over a standard job shop is my experience with building boats. I understand how the fitting will be used and can offer suggestions as to how to improve the design.

If you could give one piece of advice to a new machinist what would it be?

The advice I would give to new machinists is to start slow and learn the machines and techniques before you try to make parts quickly. There is a lot of pressure in shops to make parts as fast as possible, but you’ll never be as fast as you can be if you don’t learn the processes properly first. Also, learn to sharpen drill bits well!