Giles G-200 – Gear Leg Fairing Tooling Design

Making the overall shape for the gear leg fairings, as I described here, is really about 1/3 of the way to making the molds.  Granted, from my perspective, it’s the most fun part of the design process, but there is a lot of work that goes into taking that macro shape and turning it into … Continue reading

Finally, some Giles G-200 progress. Finite Trailing Edge Thickness Airfoils in Rhino3D

Now that we’ve got some projects cleared off, I’ve finally had time to return back to the Giles G-200.   It’s amazing to me how when you come back to a project after working on some truly difficult stuff, suddenly the things that were so hard on that earlier project are now much easier.  Such … Continue reading


The episode of ENGINEERvsDESIGNER that I was interviewed for a few weeks back is now up.  It was a blast talking with Adam and Josh about everything from reverse engineering to cake baking.  You can check it out here if you like.

48″ Convair 240 for Electric RC

My whole love affair with CAD/CAM got started about somewhere around 2004 when I decided to start building balsa model airplanes again.  I was very involved as a kid in building and flying radio control aircraft – mostly Antiques/Old Timers, which are pre WWII designs.  But, with college and work and such, there was a … Continue reading

Giles G-200: Cowling Design Progress

Well, I suppose this post is going to wrap things up for the year.  I’ve spent some time this week working on various projects, and also upgrading our office space (more on that in a week or so), but it feels good to be finishing out the last work day of the year making some … Continue reading

Impeller – Surface Rebuild

Whipped out a nice little surface model of this impeller that we scanned, and I must say I’m quite happy with the result.  Here is a screenshot of the final surface: Much of this was done with just standard Rhino commands, but the vertical surfaces of the vanes had a very slight draft to them, … Continue reading

Reverse Engineering Tools in T-Splines for Rhino Webinar – Archive Available

I had a lot of fun doing a webinar yesterday for T-Splines on the new retopo snap tools, which allow you to take a .stl mesh file, and apply a T-Spline surface to it.  If you missed the webinar, or want to watch it again, you can do so here:

PointDeviation, MinBox

Two cool little Rhino3D tricks to pass along today.  I was doing some prep work for my November 29th webcast on the new T-Splines retopo tools, and I was looking for an easy way to calculate the deviation between my T-Spline surface and my scanned .stl mesh.  I was looking around at paid options, when … Continue reading

T-Splines Webinar: New Reverse Engineering Tools in T-Splines for Rhino

I’ll be presenting a webinar hosted by T-Splines on November 29th on the ins and outs of the new T-Splines V3.3 retopo tools.  I’ll be covering the methods of taking scanned mesh data and applying T-Spline surfaces to that data.  You can register for the webinar here.  Hope you can make it!

Maximizing Toolpath Quality with madCAM

I’ve been using madCAM to generate all my toolpaths for a few years now, and I have to say I really love it.  Since the machine I use is 3-axis, I’ve been using the entry level version, which sells for $750, which puts it squarely in the “budget” range of CAM software.  That being said, … Continue reading