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The Swetman Makerspace INFO Large Tormach CNC Mill project was initiated in Spring 2025 by Kit Fox Engineering as part of the ENGR 205 Introduction to Design class taught by Qualla Ketchum and Lonnie Grafman at Cal Poly Humboldt. Kit Fox was tasked with creating three deliverables for the project. We produced (1) a video series about how to use the new Tormach PCNC 440 mill, (2) signage and printed information about using the mill, and (3) some example prototypes to display what the mill is capable of creating. The aim of this project is to teach students how to use the CNC mill and empower them to create.
Background
The Cal Poly Humboldt Makerspace is growing. New information is required to operate new machinery. The INFO Large Tormach CNC mill project is about empowering students to learn how to operate the new Tormach PCNC 440 mill, which is currently the largest mill at students have access to. We have developed a process based video series about how to operate the machine, a project video outlining how students can mill a CAD file, signage about safety, documentation about essential G-code functions, and we will be leaving behind some projects that we milled.
Problem statement
The objective of this project is to educate students to safely and competently use the Tormach PCNC 440. Currently the CNC mill is underutilized, and students who are interested in using it have no way of learning how to use it.
Criteria
To evaluate our options objectively, we identified a set of criteria that reflect both the educational goals of the video series. These criteria helped guide our decision-making using the Delphi method, ensuring that each option was assessed for its overall effectiveness, accessibility, and relevance to student needs. Notable the weight for each section were determined by our client. The following four criteria were identified by our client as central to our mission:
Criteria
Description
Weight (1-10)
Safe Procedures
Clear communication of safety protocols and expectations to minimize risk during machine use.
10
Aesthetics
Considers the visual appeal of our videos to a broad audience. Videos should appear polished and professional.
10
Digestable
Ensures that the information is easy to understand and follow, especially for students with limited prior experience.
9
Comprehensive
Covers all necessary steps and details to provide a complete understanding of the process.
6.5
Prototyping
Our initial prototype videos and physical prototypes gave us perspective on what it would be like for students taking their first steps into CNC. We encountered and resolved many issues that we were sure to include solutions to in our videos, signage, and documentation in order to ease the learning process for future students.
Shown below are just a few examples from our prototyping process.
Prototype Gallery
Tormach CNC milling our first prototype axe head fidget spinner.
This is a Turner's Cube drawn in Autodesk Fusion 360
Tormach CNC Operational Procedures
Final product
A sign reminding students to clean up swarf—machined waste chips—after using the machine.
Our final design is the production of a series of 5 videos based on the process of using the Tormach PCNC 440, a specific project video, signage, documentation, and prototypes of what the CNC mill is capable of creating.
An example physical prototype of a fidget spinner, showcasing achievable machining tolerances through a press-fit bearing and demonstrating the machine’s ability to produce smooth surfaces using a ball end mill.
We designed and printed magnets of three key pieces of safety signage to be displayed on the machine to remind users of the machine about the safety and maintenance expectations that come with using the machine. These signs are thin magnets that can be easily taken on and off of the machine.
Documentation
We made reference documents to go with the machine so that users could easily reference important information. One of these documents is entirely dedicated to turning the machine on and off as it is a somewhat complicated procedure and the other is a list of important G-code commands that any CNC user should be familiar with.
Prototypes
Not to be confused with our prototype videos these were meant to be physical objects displayed with the CNC machine that demonstrate the capabilities of the machine and also captivate students who are interested in the machine, encouraging them to recreate the prototypes or design their own CNC projects.
Construction Process
Drill Bit Index, demonstrates the width of cut and finish for different drill bits
When making informational resources for the PCNC 440, it was of top priority for the material to be accebile to the broadest amount of people. That meant assuming the general audiunce consuming the inforamational resorces had zero experience with machinery. Making the informational resources digistable and informative is of equal importance as ensuring their accesibility.
When making the physical prototypes, we wanted students to want a physical prototype for themselves, leaving them encouraged to follow through with learning the Tormach PCNC 440.
Bill of materials
The materials needed for this project mainly consisted of the stock material and drill bits need to mill with the Tormach PCNC 440. The remainder of the costs associated with the project went towards materials needed to display the informational resources and safety signage.
Item
Amount
Costperunit
Total
Hose Clamps —
1
USD2.99
USD2.99
Scotch Blue Masking Tape —
1
USD9.99
USD9.99
Loctite Super Glue —
1
USD13.14
USD13.14
1/8 3F Flat End Mill —
1
USD19.99
USD19.99
Magnetic Printer Paper —
1
USD8.99
USD8.99
Stock Metal — Total price of all the stock metal we bought throughout the course of the project (sourced from multiple vendors)
Operation of our projects involves watching our free videos on Youtube.com, reading our signage and documentation, and viewing our prototypes that will be displayed with the machine.
The Youtube Chanel contains two different playlist, a project based video series and a process based video series. The process based video series were made in a effort to teach students about the Tormach PCNC 440 and it's capabilities. The project based video series was made in hopes of having students follow along as they complete their own version.
1
Process Based Video Series
2
Project Based Video Series
Maintenance
Some maintenance will be performed by students and some maintenance will be performed by staff. It is the duty of anyone operating the machine to do so safely and to leave the work area clean.
Maintenance schedule
This section describes the maintenance schedule for the Tormach PCNC 440.
Daily
Make sure CNC mill is off when not in use
Make sure that CNC mill is clean and ready for use
Clean the way covers of chips.
Clean the chip baskets on the coolant tank.
Examine the coolant level and condition.
Examine the way oil level and refill as necessary.
Retract the plunger on the manual oiler, hold it in the retracted position for two seconds, and then release it.
If you have pneumatic accessories installed (like a Power Drawbar), verify that the regulator has at least 90 psi compressed air.
Verify that the door switches are properly functioning.
Weekly
Clean all exterior surfaces with a clean rag.
Verify that the machine's lubrication points (sliding surfaces and ball screw nuts) are receiving way oil.
Examine the enclosure and other guards for damage.
Examine the drawbar for wear.
Examine the Tormach Tooling System (TTS) collet for wear.
Remove vises, fixture plates, rotary tables, and other accessories, and then examine them for rust. If needed, reapply the rust inhibitor before reinstalling work holding and accessories.
Check coolant concentration.
Monthly
Clean the electrical cabinet vents of dust with a clean cloth or compressed air.
Clean fine swarf from the coolant tank.
Examine all axes' slideway surfaces and ball screws to determine if an oil film is present.
Examine the air tool oil level in the FRL Filter-Regulator-Lubricator and refill as necessary.
Conclusion
Testing results
We shared the videos, prototype examples, and documentation with a broad group of people in an effort to get more diverse feedback. The work was shared with staff, students within the Engineering department, with friends and family outside of the major. The feedback we received helped us better understand where more attention was needed in the videos or future physical prototypes. It is important to receive feedback from a diverse group of people, as we are assuming that people learning how to use the CNC machine at school have little to no experience with operating machinery.
Discussion
The testing results gave us ideas for improvement that we implemented. Based on suggestions we made the following improvements to our final products:
Scripted the video narration
Better angles of the CNC
Screen share video of the PathPilot program
Simpler signage
Ideas of what else to include in the documentation
More detailed prototypes
Lessons learned
Our videos and instructional content were largely informed by the mistakes we made while learning to use the CNC and by feedback from others. Some lessons learned are:
Make sure work clamps are far out of the way of the tool path
Double check the CAM file criteria to make sure that your cuts won't be too deep or that you have the proper tool selected
Clean, simple videos with good audio were best
Point-positive instructions are key to success
Next steps
We have started the CNC and Manufacturing Club to further empower students who wish to use the CNC machines. We hope to gain access to other machines like the CNC lathe and help students bring design ideas to life.
Troubleshooting
Troubleshooting the Tormach CNC. (Contact Makerspace staff, or the CNC and Manufacturing Club with issues beyond the scope of this table.)
Problem
Suggestion
ATC is not working
Check to see if there is adequate air pressure (90-120psi). Turn on compressor if low. Use regulator if high.
Does not turn on
Make sure everything is plugged in.
Tool length is incorrect
Did you select the proper tool number in CAM? Does that match the tool on the ATC? Double check tool dimensions with height gauge. Make sure this measurement matches the measurements entered in PathPilot and in the CAM file.
Team
Kit Fox Team Photo
ENGR 205 Intro to Engineering: Spring 2025 Semester
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