This is an update on the progress of the SPY005 project. Other CPF threads on the SPY can be found here.
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The machining of the first few prototypes of the SPY005 body is complete. I am on schedule and have started work on the bezel assembly. The knob is being done by another shop and should be complete next week. The last piece to be made will be the end cap.
The machining of the body is the most time consuming and costly of all the parts. It was done first so I could gauge the progress of the entire project. If you are into machining and want to know more about the setups I will go into more detail. Here is a little quantitative information on the machining of the body.
These pictures show what the body of the flashlight will look like. No more machining or finishing work is needed. The Aluminum 6061 T6 material will be hard anodized with the HAIII natural color. As most people know it is a dark flat gray finish that changes the look of a piece of machined aluminum considerably. It will not be shiny as in the pictures below.
- Programming and setup took over 100 hours.
- There were three milling machine setups. Machining from battery end, then from bezel end and finally the rotary table was used to machine the sides (shown below).
- Total machining time to complete one body is 70 minutes (it will drop as the process is optimized).
- Total number of tools used in the mill is 26.
- Total number of job steps programmed in CAM software was 70.
- Total number of fixtures designed and machined was 3 (one can be seen on the rotary table below) it needed accuracy to 0.001” to align properly.
- Total number of cans of Coke consumed was not counted.
The last two pictures show one of the fixtures used to hold the part during machining. The inside of the body has a ledge machined in it that the “T” bolt slides into.
I am working or a video I took of the last step of the machining when the rotary table was running. Check back later for that.