Formula SAE Rear Uprights

After learning Esprit 2010 CAM software, we have been using this to create rear uprights for the Formula SAE team. It has been a huge learning experience, including multiple failures and problems along the way. A huge problem arose when trying to post process the code from Esprit to the Acu-rite controller for the Bridgeports in the shop. After re-writing and editing a generic 3-axis post processor for Esprit (again including many trial and error failures) we now have a working post processor for our setup. These uprights are milled out from a 4 x 8 x 1.8" block of aluminum. Much of the material is removed using 4 tools including roughing, ball and flat end mills. Posted below are pictures that document the process from solid model, to CAM tool paths, to final part (well almost final, final pictures will be updated soon).

Control Parts for Second Build

So I decided that I should invest in some new bearings, shaft collars and couplers for my second machine. Purchased some pretty basic stuff, Lovejoy couplers one side 1/2" the other 1/4", 1/2" shaft collars for the lead screws and some 1/2" ID bearings for the 3 axes. Bearings were from Ebay while the collars and couplers were from McMaster Carr; in all I think I spent around $35 for everything.