The final puzzle assembled with lid. Ball (a copper BB) is resting in one of the goal holes.

The randomly generated terrain before being decimated in MeshLab.

The terrain in Solidworks after being decimated. Green surface is the surface modelling done by hand, purple the generated terrain.

Toolpath in HSMWorks for the first pass with a 1/2 inch ball end mill.

The terrain being milled out from the center of what started as an aluminum block.

Stock simulation in HSM based on the time depicted in the photo above.

Toolpath for the final pass showing the depth of the terrain and quantity of tool retraction and movement. Cut was made with a 1/4 inch ball end mill.
Using a combination of Solidworks CAD & HSMWorks CAM software, I created models, toolpaths, and gcode for our CNC machine. Running the machine, changing tools, and troubleshooting toolpath & procedure settings helped me understand contemporary manufacturing processes.

<---- My final project is a dexterity toy using procedurally generated terrain  and surface modelling to create a rolling surface for a ball.

I drilled spots for the ball to rest in (goals for the player) at the top of the peaks and custom lasercut the top acrylic lid. Selected, tapped, and drilled holes for screws to tight tolerances.

This terrain-inspired project was modelled in layers like a cake and joined using multiple lofts.

Toolpath in HSM for the final pass using a contour procedure.

Each layer with multiple towers required separate sketches that fit previous sketch boundaries and all the lofts to be properly aligned.

My first project, a fidget toy with a track designed to fit the head of a screw. Nut on other side of the slot secures it, allowing it to slide around. The corners each use a different curve algorithm.

My two sides project, which required us to machine one side, flip the workpiece manually while maintaining zero, and machine the other side. Due to the complexity of the modelled curves it turned out to be a nightmare. But I learned from this failure. And hard work with a file fixed the seam lines.