This project was born out of a desire to fix a vegetable steamer which had broken handles. The photos and type below detail the process of designing and making replacement handles in Oak using CAD modelling, CNC milling, 3D printing (for jigs) and some more traditional processes.
Initially I surface modelled the handles from hand sketched profiles using SolidWorks. Next I imported the files into Fusion 360 where I programmed the CNC milling machine.
Each side took approximately 2 hours and was comprised of roughing and finishing operations for efficient use of the tools. I aligned the stock to the milling bed using 6 x 6mm positioning pins. This allowed me to flip the stock over and machine the other side, since the position of each pin were known values to the CNC.
After milling the pan handles it was time to produce the lid handles. I chose a lollipop cutter to add an undercut since I did not have assess to a wood lathe. The cutter produced some burning which was removed by hand sanding afterwards. This was because the cutter was designed to be used for metal rather than oak, despite using a low spindle speed.
Each handle needed to be cut from the remaining stock using a band saw. This was a small price to pay for the ease of clamping to the milling bed, allowed for by the rectangular work piece.
I produced a jig in order to hold the handle for subsequent machining processes. The jig was produced using an FDM 3D printer for speed since tolerances were not too critical.
Once final milling pass was completed inside the handle to allow the pan fixing to slot inside. After 3 coats of raw Linerseed oil, the steamer was assembled and photographed. Enjoy...