Really, everyone should have a skull on their desk.  It's an age-old symbol, a memento mori that reminds us that we are not long for this world.  So I set out to make one out of aluminum.  This was my process.  

Step 1: CAD/CAM

I designed the skull in Solidworks.  I don't have a ton of images from this part, and surface modeling is a giant can of worms that I'm nowhere near good enough at CAD to properly explain.  I got most of my help from the Solidworks Surfacing Bible, which can be purchased here.  If you're interested in my methods, take a look at the attached Solidworks file.  

I did the CAM setup in CAMworks.  This was divided into a rough area clearance, a z-level, and a constant stepover finishing pass.  I chose to do the rough clearance with a 1/2" hogging end mill, the z-level with a 1/2" regular end mill, and the stepover with a 1/4" ball end mill.  
This is great! I did a whole series as an undergrad with the <em>Memento mori</em> theme, I'm a sucker for such things. Well done!
<p>Yes! I would like to see the codes too! :-)</p>
looks pretty good!! i have featurecam but not in 3d, can you send me cnc text file? <br> <br>thanks
could you please add the (STEP) file as well.
hi, would you be able to upload an (STL) file as this would be very usefull, thanks.
That looks like a great surface finisher. Nice work as well. My husband has just recently got into projects like this as well. His new favorite idea and tool is <a href="http://www.abrafast.com" rel="nofollow">portable surface finisher</a>.He love that he can take it anywhere with him and fix it up in a jiffy. Thanks for sharing your awesome creation and work!
It will be nice if you can put a STEP, IGES or Parasolid files so every CAD/CAM system can open your model and not only Solid Work. <br>For the rest, good job on the model and the fabrication.
I've added an IGES file of the model; If you're still unable to open it, let me know, and I can try something else.
Yeah, I can't open whatever kind of file that is in Mastercam.
Unfortunately, I don't have access to CAMworks right now, so I can't mess around with its data formatting. I will have a more accessible CAD file up soon, though. Thanks for reading and commenting!
i try something like this whenever i can.....but im more of a trail and error kind of man, sooooooo no computer for me.
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Sweet dude! I might have to try this. Nice guide!

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Bio: I'm a first year product design student at Hampshire College. I know how to make lots of things, and I can usually figure things ... More »
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