Helps Designs — 3D Printed Jigs

Carbon Fiber Drilling Jig

During the early development of the StoneForge 3D Printer, I faced a unique challenge: I needed to drill dozens of 15mm holes in 40x40 and 80x80 aluminum profiles—without access to a professional drilling machine. Instead of waiting, I engineered a drilling device that allowed me to precisely drill the holes.

Using the same aluminum extrusions destined for the final build, I created a setup that featured a 3D-printed nylon carbon fiber jig. This jig slides on three 40x40 aluminum extrusions that work as linear guides, while a 3D printed carbon fiber component holds the drill at the exact required distance.

Not the perfect solution, but an immediate and functional workaround that kept the project moving forward.

Gen Shelf

Generative design is a computational technique that leverages algorithms to autonomously explore a broad range of design solutions based on specified goals and constraints. Rather than manually crafting each iteration, designers input critical parameters — such as materials, loading conditions, performance targets, and spatial constraints — into specialized software.

The software then generates numerous optimized configurations, often revealing innovative solutions that might never have emerged through traditional design methods. This process significantly accelerates the design cycle and effectively harmonizes aesthetics, functionality, and efficiency.

Driven by curiosity, I explored generative design through a mini-project focused on shelf brackets using Fusion 360’s generative design simulation tool. I began by defining an initial geometry serving as the interface between the shelf and wall, complete with pre-determined holes. The software required me to set constraints, allocate adequate space for screws and tools, and specify load conditions. Additionally, I experimented with a diverse array of materials to broaden potential manufacturing options, given that the software does not yet directly support Fused Deposition Modeling (FDM) processes.