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The Hocus Focus
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* June 02, 2009, 09:04:56 AM
Here are some pictures of some of the 3D parts I have designed for the Hocus Focus, which is a remote focusing device for film cameras.










All done in Turbocad Mac deluxe. Parts were CNC milled and EDM wire cut using IGES and DXF export files.

We are cutting some bits out on a five axis mill from TC drawings soon.

Turbocad is quite a powerful tool when it can control this monster: (thats an F1 wheel hub being machine from solid (although I did not design it, just thought it was a cool picture)

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* June 02, 2009, 03:15:28 PM
#1
Fantastic stuff

Thanks for sharing it.

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* June 03, 2009, 05:53:46 PM
#2
So I went to the machine shop today to see them milling out the aluminium version of the plastic parts in the first few photos.

These parts were milled directly from the iges files straight from Turbocad Mac Deluxe v4.




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* June 04, 2009, 09:32:26 AM
#3
Thank you for posting these great pictures...

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* June 04, 2009, 12:03:19 PM
#4
Quick update.

Went to pick some more parts up today.









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* June 16, 2009, 05:38:26 PM
#5
We have now started a run of 28 pieces of each part. Heres some nice pics...




(part is held upside down in a specially made positioning jaw)



The parts shown on the screen here are being cut out on a five axis pallet loading mill. It has a rotating stage of 10 work tables outside of the machine, and it automaticaly loads the table in to work on it. This is so you can load up 10 jobs in advance and never stop the machine running. This machine is working overnight, as we speak making 28 motor chassis, should be done by about 3am. These plates will then be removed, stuck in the wire machine and the outside shape will be wire cut with a .2mm brass wire.

All tolerances are about 10 microns.
All drawings done in Turbocad Mac Deluxe, exported as an IGES file then imported into the CAM system, programed and milled direct.
« Last Edit: June 16, 2009, 05:40:08 PM by Hocus Focus »

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* June 17, 2009, 05:37:56 PM
#6
Update,

The plates seen in the above posts were made overnight, but unfortunately one of the taps was damaged and the threads are misplaced by about 10 microns (0.000393700787 inches) so all four were rejected and are being re made tonight. This does mean that I took one of them home to stick on my windowsil,


The holes at the bottom of each part are starter holes for the wire cutter wire.

There are seven chassis cut from one plate, the pockets and threads are cut first, and then the outside shape is wire cut. Each plate takes four hours to machine 12 hours to wire cut, and the circular clamp bore is cut to 3 micron tolerances (0.000118110236 inches)

(this is the part these plates will end up being)
http://photos-d.ak.fbcdn.net/photos-ak-snc1/v4721/127/96/506442569/n506442569_1802931_3940161.jpg

The back caps are now complete, and looking very nice. Going to the anodisers tomorrow.




All going well, will have some more bits in soon.


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* June 19, 2009, 04:31:34 AM
#7
The flat plate above has now been cut out.





Wire machine at work. The spark is the electrical arc that erodes the material away. Each plate takes 12 hours and uses about 16-7 miles of wire.

Note the thin fin of aluminium still supporting the plug from the clamp.
« Last Edit: June 25, 2009, 07:27:15 AM by Hocus Focus »

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* July 10, 2009, 02:44:18 PM
#8
Some more pics,

The caps shown above are back from the finishers,


Pointers are done (the top arrow is milled in with a 1mm dia end mill and the two M2 threads in the back were put in manually)


The motor chassis have been blasted and were sent to the finishers today.



All coming a long nicely.

All designed in TC mac Pro Deluxe v4.

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* August 25, 2009, 10:16:13 AM
#9
So finally after all the design and development stages, the Final Hocus Focus is finished.







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* February 17, 2011, 08:45:55 AM
#10
WOW! I'm new to all this and I've got to tell you.....I AM INSPIRED! Thank you for presenting such a complete utilization of this wonderful tool.

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