MECHANICAL · MACHINING · CAD
Machined multitool
Birdie is a compact multitool machined from aluminium stock on a Haas Mini Mill. Three functions packed into one part: a 50mm ruler, a crown cap bottle opener, and hex key fits for M6, M5, and M4 fasteners. The project covered the full workflow from CAD design and GD&T tolerancing through CAM toolpath setup and hands-on machining, with careful attention to datum selection, feature tolerances, clamp placement, and surface finishing.
Course
IPD 5010
Machine
Haas Mini Mill
Functions
50mm ruler · bottle opener · M6/M5/M4 hex keys
Material
Aluminium stock
The central hexagonal cutout was chosen as Datum A. Key locating features were assigned profile tolerances of 0.005 relative to that datum, surface straightness was called out on the ruler edge, and the hex key holes were dimensioned directly from bit sizes to ensure a tight, functional fit.
The main challenges were sizing holes precisely to bit dimensions, managing how bit rest plane height affects total machining time, planning clamp placement to keep the stock properly aligned during each operation, and accounting for material removal during deburring when setting engraving depth.
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