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>4 or 5 Axis CNC Router </p>
<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.
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.
Sweet dude! I might have to try this. Nice guide!

About This Instructable




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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