Step 1 - Receive detailed specification from client
Initially a detailed specification from the client was received. This outlined the key dimensions of the part, and the specific load the geometry should withstand.

Step 2 - Research stock material sizes
By designing a part around stock material sizes, time and money are saved as less machining time is required to cut the stock down to size.

Step 3 - Solidworks model
Using the stock sizes and client specification, a 3D Model was made up from which engineering drawings were created.

Step 3 - Finite Element Analysis (FEA)
Using the 3D model, maximum loads were calculated and then applied to the part under the correct constraints. The part was then altered adding or subtracting material in different areas in order to create the optimum design (high strength, low weight)

Step 4 - Cutter paths in FeatureCAM
The outer segments were then imported straight from solidworks into FeatureCAM, where their geometry was converted into cutter paths which can be interpreted by our machines.

Step 5 - Machining
Using the generated paths from featueCAM, and the engineering drawings, the individual parts were then machined which involved both the turning and milling processes. Step

6 - Welding & Assembly
The individual components were then pinned, and welded in place, in order to create the finished form.