Manufacturing & Machining
Machined research and recovery hardware on CNC and manual machines, fabricated aircraft composites, and taught BURPG members turning and milling through the machinist’s-hammer project beginning in Fall 2025.
CNC Milling: Shaker Adapter
Machined the 6061-T6 shaker adapter on a Haas VF-2, including 12 drilled holes held to ±0.005 in. Finished mass: 1.90 kg from 3.19 kg stock. Used CAM-generated G-code, GD&T, ISO hardware clearances, and tolerance-stack analysis; the Plummer page contains the design trade and analysis.
View the Plummer machining work
Manual Machining: Recovery Hardware
Redesigned the Catclaw cable cutters, created an engineering drawing, and machined their aluminum bodies on a manual mill and lathe. Separately, I contributed to the design, drawings, fabrication, and testing of the CO₂ deployment piercers.
View the cable-cutter machining
View the CO₂ mechanism’s design and manufacturing
Composite Fabrication: AIAA Aircraft
Contributed fiberglass fuselage layups, balsa airframe and Clark-Y wing fabrication, and detailed internal-wing CAD for the 2024–2025 competition aircraft.
BURPG Machining Intro Project
- Machinist’s Hammer: Turned an aluminum handle and milled an HDPE head. The training drawing called for ±0.001 in tolerances; no feature-by-feature inspection record is presented.
Beginning in Fall 2025, I taught other BURPG members hands-on turning and milling through the Machining Intro Project (MIP), using this machinist’s hammer as the training build.
My MIP machinist’s hammer: turned aluminum handle and milled HDPE head