Nifty CNC Machining

Nifty CNC Machining custom parts design and manufacture using a Hitachi Seiki CNC HiCell CA20 turn/mill Lathe with full conversational control of all 4 axis XYZC

custom parts design and manufacture using a Hitachi Seiki CNC HiCell CA20 Lathe with 4 axis XYZC

My least favourite time of the year that is unavoidable, downtime for maintenance is now past. As a young apprentice, I ...
22/12/2025

My least favourite time of the year that is unavoidable, downtime for maintenance is now past. As a young apprentice, I was bewildered by the old tradesmen that were always bitching & complaining & grumpy for this n that. Most of which wasn't much at all. No one prepares you for what is to come with older age.....aches & pains, where they shouldn't be. If you do decide to get down on the floor on your knees, or lay down to get to the conveyor tank, you best have a backup plan to return to a standing position. Growing older sucks, 40 years ago I could clean the machine completely top to bottom, remove the coolant tank and swarf conveyor, clean that thoroughly and have it all reassembled back up and running in less than 8 hours. It's just taken me 3 days to do the exact same machine and job.
Anyone that's ever stripped a CNC machine down for maintenance or cleaning will know all too well, they are just nasty. There's swarf buildup, oils, grease, coolant, lost tools & small parts in every imaginable place they just shouldn't be. Good news, I found my missing torch, batteries were flat though.
Many machines appear pristine on the outside, remove a cover or 3 and you will unearth a festering swamp that has a smell all of its own and refuses to support any form of life that is non lethal. I let the Hicell go 2 years, as a trial, it was not as bad as I expected. I do believe that because I only use our own rain water supply, not mains or scheme as we are off grid here, that the machine itself does not rust or suffer the ill effects of the chemicals in town water supply. I've seen some disgusting machines in the past, with only a few months use on them.

On a side note, I now know that under the machine was the final resting place for a large proportion of the local millepede population. If anyone has a solution to keep them outside, let me know. I've tried many products, all failed.

Well, time for a short break, then back into it next year.

Thanks to all that have shown an interest in what I do, cheers.šŸŗšŸŗ

Last job for this year complete. Medical thumb screws, machined from stainless steel, drilled & tapped M8. Time for some...
21/12/2025

Last job for this year complete. Medical thumb screws, machined from stainless steel, drilled & tapped M8. Time for some long overdue maintenance....😭

When reproducing components by traditional machining methods, it is not always possible to create certain geometries wit...
18/12/2025

When reproducing components by traditional machining methods, it is not always possible to create certain geometries with available tooling. Especially when the part has been injected moulded, or 3D printed. I'm not making excuses here, but the Hicell is not a fancy modern piece of tooling that is user-friendly or does it all for you with no human brain intervention. You are what drives it, and it is you that creates the CNC code by hand, typing each character or number individually, using trial and error, to see what works and what does not. It has its limits. I reach it often. For an early 1990's machine to even be capable of certain tool paths is amazing. The books actual show what is possible and what is not, so, challenge accepted, let's make it do what it was not built for. Sometimes the tooling, job geometry, tool nose radius compensation and tool path do NOT play well together and you just have to break it up and try something else. It takes time, but we got there. With this black acetal plastic job, it didn't need to look pretty, just resemble the supplied oem part. I did the best I could with what I had available. 1mm milling cutter was a challenge to get it to cut 8 times diameter depth. The rest of the job was fairly straightforward. I have no idea what they are, so shall hence forth be known as medical professionals douvalki thingamajigs.

When I searched back through my records and programs for this repeat job, I was shocked to see its been 11 years since t...
05/12/2025

When I searched back through my records and programs for this repeat job, I was shocked to see its been 11 years since the last batch. Not a common job at all. I made the 1st batch in 1993, did a few batches until 2014, now just replacements, not the full build. These are spray injection nozzles machined from brass hexagon bar. Thread is M6, nozzle hole is 1.50mm, lengths are 46mm and 81mm. I'll probably be retired before Machining these again.

These are the black acetal milled block split clamps for medical equipment. Very fiddly little parts done in a single op...
23/11/2025

These are the black acetal milled block split clamps for medical equipment. Very fiddly little parts done in a single operation. I actually ran out of live tool holders for the X axis on this job, it's more complicated than it appears.

23/11/2025

This is only a part video showing the chamfering process of a small milled block that is a split clamps for medical equipment. This code I wrote entirely by hand as it's much quicker and easier than other forms of creating code for toolpaths.

1 off random shaft and housing with M10 cross drilled and tapped for location. Machined from K1045 mild steel.
23/11/2025

1 off random shaft and housing with M10 cross drilled and tapped for location. Machined from K1045 mild steel.

Repeat jobs dating back alot of years. M10 x 1.0p fine brass screws and het nuts. The spacers are white acetal.
23/11/2025

Repeat jobs dating back alot of years. M10 x 1.0p fine brass screws and het nuts. The spacers are white acetal.

This is typically how most medical components land on my work bench…..in multiple pieces. This one off job is some sort ...
13/11/2025

This is typically how most medical components land on my work bench…..in multiple pieces. This one off job is some sort of surgical instrument that has this plastic gearbox labyrinth that connects it all together. It has cover plates, bearing portals, axle location, mounting flanges, etc. all in one very compact yet fragile part. I copied it as best I could from the damaged unit. Machined from black acetal. The interesting part is that none of this job was done using the machine’s own conversational programming system, nor was any cad/cam system. The Hicell does have very limited conversational capability but not pocket milling. That wasn’t even thought of in 1993, so I find it easing to write the code by hand. I did it the fastest way I know, the old way. Pen, paper, vernier, calculator and AI……That’s ACTUAL INTELLIGENCE, not that new fangled bu****it algorithm software disguised as something it is not. The entire code was hand typed in my old text editor using MS-DOS 6.2, old trusty never fails me. No updates, no bugs, no glitches, no waiting to load, no log ins. It just works simply, as it should. CNC G code is very simple if you know what you want to do, it only gets complicated if you let it. The only modern part of this process is using a PC instead of blue punch tape (shudder), I do not miss that life, one mistake with my fat digit typing single characters and you start the entire program again. This job worked out well and will get the customer out of trouble and back in surgery faster than they expected.

13/11/2025

This is typically how most medical components land on my work bench…..in multiple pieces. This one off job is some sort of surgical instrument that has this plastic gearbox labyrinth that connects it all together. It has cover plates, bearing portals, axle location, mounting flanges, etc. all in one very compact yet fragile part. I copied it as best I could from the damaged unit. Machined from black acetal. The interesting part is that none of this job was done using the machine’s own conversational programming system, nor was any cad/cam system. The Hicell does have very limited conversational capability but not pocket milling. That wasn’t even thought of in 1993, so I find it easing to write the code by hand. I did it the fastest way I know, the old way. Pen, paper, vernier, calculator and AI……That’s ACTUAL INTELLIGENCE, not that new fangled bu****it algorithm software disguised as something it is not. The entire code was hand typed in my old text editor using MS-DOS 6.2, old trusty never fails me. No updates, no bugs, no glitches, no waiting to load, no log ins. It just works simply, as it should. CNC G code is very simple if you know what you want to do, it only gets complicated if you let it. The only modern part of this process is using a PC instead of blue punch tape (shudder), I do not miss that life, one mistake with my fat digit typing single characters with one finger and you start the entire program again. This job worked out well and will get the customer out of trouble and back in surgery faster than they expected.

07/11/2025

Survey time…bosses / managers / directors of companies….we’ve all had them. Mostly they are beyond useless when it comes to real work. Not much help on the actual workshop floor at all, if ever. These days, they generally are brilliant at polishing a chair or preventing it from blowing away. My 1st boss was different. Once his office duties were complete, he’d flick his tie (yes, tie) over his shoulder and debur or drill holes on a very old pedestal drill. He’d even help clean, sort, count and pack jobs. You know, the menial tasks, but those that actually help in the production process.

So, who still does this? Does anyone’s boss help on the workshop floor? Do they get their hands dirty?

Well, today I was pleasantly surprised. The Nifty CNC Machining company director impressed me. I arrived home to find my workload all caught up to date. Not only had the director deburred every single brass spacer, but also sorted the swarf, washed them all and laid them out to dry ready for counting and packing. WOW! The only thing left to do, was run the last few brass bars and wash the machine down. This saved me many hours of catchup time. More beer time as well.

The real kicker is…for those that don’t know, the Nifty CNC Machining company director is my beautiful wife Nerissa. She has earnt her keep this week. I may just keep her on a little longer.

Another small repeat job completed. These are machined from black acetal. They are a shroud for medical grade tweezers u...
04/11/2025

Another small repeat job completed. These are machined from black acetal. They are a shroud for medical grade tweezers used in surgery. The 2 small offset holes in the blind end are for the probes to protrude.

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Bullsbrook
Perth, WA
6084

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