Torpedo Level

Summary
I designed and machined a custom torpedo level with three precision-aligned angles and a functional V-groove for pipe work. I modeled the entire design in SolidWorks, programmed the toolpaths in MasterCAM, and machined six levels on a CNC mill. To hold the part securely, I made custom soft jaws that matched the profile, and I embedded magnets in the base so the level could attach to metal surfaces.

Goals
My goals were to build a compact, accurate level with clean aesthetics and to learn how to integrate multiple vial angles into a single milled body. I wanted the V-groove to work well for round stock alignment, the magnets to sit flush without interfering with the vials, and the machining process to be efficient and consistent across all six units. Another goal was to gain experience with the full workflow from CAD to CAM to machining with custom workholding.

Challenges
A major challenge was aligning the three angle pockets so each vial seated correctly. Even small tolerance errors would affect accuracy, so precise toolpaths and finishing passes were important. The custom soft jaws also had to hold the part securely without causing distortion.
Another challenge was machining the V-groove and magnet pockets while keeping everything square across multiple setups. The part required features on several sides, so I had to plan the operations carefully and verify that each setup matched the model. Balancing precision, workholding, and repeatability made this a valuable project for sharpening my CAD and CNC machining skills.

Details

Precision Machining: Geometry, Angles, and Vial Placement
I planned the three-angle layout in SolidWorks and built the entire design around the vial orientations. Each pocket had to line up perfectly, so I created toolpaths in MasterCAM that kept the pockets flat and consistent. I ran test cuts in scrap to confirm the angles and depth before machining the final six parts. Once everything checked out, I monitored tool wear and repeated the operations to keep all six levels identical.

Workholding Engineering: Custom Soft Jaws and Multi-Side Machining
Because the part has features on several sides, standard workholding would not work. I designed custom soft jaws that matched the profile of the level and held it securely without damage. This setup let me machine the top, bottom, and angled faces while keeping a consistent zero point. The snug fit of the jaws kept every feature aligned through each setup.

Functional Features: V-Groove, Magnet Inserts, and Practical Use
The V-groove on top was added for working with pipes and round stock, so I made sure it had a clean finish and a stable angle. I also machined pockets for magnets in the base and epoxied them in place so the level could attach to metal surfaces without sticking out. These features turned the part into a useful tool rather than just a machined block.

Production Workflow: CAD, CAM, and Six Matching Parts
I treated the project like a small production run. The SolidWorks model guided each setup, and MasterCAM handled the operations for all six pieces. I focused on repeatability, clean transitions between setups, and consistent finishing passes. Running the parts back to back helped dial in the process, and the final pieces matched each other with tight tolerances and clean edges.

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