Beyond Traditional Machining: Hitting All the Right Notes in Custom Manufacturing

It feels right and the tone is on point, but it is not an average electric guitar, and it wasn’t made the traditional way. This instrument was carved out of 140 lb of solid aluminum using computer-aided manufacturing (CAM) software from Mastercam and computer numerical control (CNC) machining processes. It comes from the house of Dean Zelinsky, a legendary wooden guitar maker whose work is used by the likes of Johnny Depp and Zakk Wylde (of Ozzy Osbourne fame).

With a background in woodworking with metalworking tolerances, Zelinsky worked with Mastercam to create a metal replica of his iconic Italia guitar to show that embracing the combination of artistry and technology with precision machining makes it possible to be as creative as you want to be—even with a musical instrument.

Traditionally, machining is associated with industries such as heavy machinery, aerospace and automotive. Now, digital transformation  is driving the evolution of precision machining across industries. From custom guitars to golf clubs, intricate designs are brought to life using CAM and CNC—solutions that allow both engineers and artisans to dream big and streamline the production of highly complex, precision-crafted items or devices.

READ MORE: Elevating Precision Manufacturing with CNC Micromachining 

Case in point: Zelinsky’s unconventional guitar. Known for his distinct, expressive designs and the unique tones they produce, Zelinsky decided to take his craft in a bold new direction by collaborating with CNC machinists and a CAM software design to recreate his iconic Italia model—this time, out of aluminum. It even weighs the same as a guitar made from wood.

Challenges in the Details

Creating a hollowed-out aluminum guitar presented numerous technical challenges, starting with the need for approximately 20 million lines of code to guide the manufacturing process. Achieving the durability of wood without making the guitar excessively heavy was one of the main obstacles; the target was to match the weight of Zelinsky’s Italia guitar, which is approximately 8 lb. To meet this goal, the project’s team used CAM software to generate the extensive code needed, enabling precise control over each detail.

The unprecedented design of the Zelinsky guitar project is composed of just three main pieces, requiring machining technology to overcome design and material challenges. The project utilized Okuma America Corporation’s advanced Super-NURBS settings, which enabled highly accurate and smooth machining paths necessary for creating the guitar’s complex contours.

The project also relied on machining technologies like the SpinJet Micro and MULTI-MASTER T-slot tools from ISCAR Metals. The RockLock system from 5th Axis was used to secure the guitar body during machining, supporting the intricate cuts required for features like vented ramps and a honeycomb structure. The honeycomb design on the guitar’s underside allows it to retain the right balance of durability, weight and resonance.

Thinking Outside the Box

It is now easier to produce one-off custom pieces and limited production runs. Machinists can work with everything from lightweight composites and unconventional alloys, as well as metal, to create complex designs such as lattice structures and complicated internal cavities, which were previously impossible or cost-prohibitive.

CAM and CNC solutions can be used to create prototypes and test equipment before mass production begins. For example, editing 3D models of custom golf club prototypes and machining them quickly can be a challenge. With strict weight specifications, the finishing phase for a custom golf club can recur several times before a part is ready for testing.

COBRA Golf, Inc. uses software to make design adjustments without having to permanently change the coding. The cutting technology can create multiple toolpaths from one original toolpath. This technology also differs from traditional cutting methods that use just the nose of the tool because it enables the use of the entire flute, creating faster cuts and minimizing machine vibration.

Precision machining provides the type of flexibility to create a custom hockey mask, as experts from GROB Systems and Emuge-Franken did as an educational tool. They demonstrated how CAM and CNC solutions can enhance the comfort, protection and aesthetics of a goalie mask. The project highlighted how CNC processes can enable better weight distribution and a snug, secure fit.

In a whimsical departure from traditional applications, Hermle and OSG USA helped to create a metal gingerbread house using CAM software and CNC processes. For the intricate hanging icicles on this piece, the project’s team used a specialized technique to shape the metal precisely. Without these techniques, the design would just look like a plain box. Using a unique tool that could move all around the shape, the team managed to avoid hitting the delicate icicle shapes and window details inside the cut.

To create a detailed pattern on the gingerbread house’s roof, the team first programmed it with a simpler three-axis machine. This method helped to lay out the design before switching to a more complex five-axis machine, which permitted a tilted chimney to be added. Though it’s a less common approach, starting with a basic three-axis plan and then carefully adjusting for safety proved to be a very effective way to work with a multi-directional machine.

READ MORE: Making the Jump to Multiaxis Machining

The project’s team also faced challenges making metal look like snow. Snow patterns are very irregular and include tiny, angled shapes that make smooth cutting tricky. To keep the tool steady while cutting in all directions, a smoothing function was utilized to reduce any abrupt changes and create a cleaner final look.

Applications Across Industries

There are so many interesting designs that can be made with precision machining, but these unconventional creations serve a larger purpose by showcasing the potential to produce intricate, highly customized items that combine form with function. These innovations can help open new avenues for experimentation, enabling rapid prototyping and enhanced adaptability.

Embracing this new era of precision machining across industries means encouraging ongoing exploration, clarity and collaboration—helping to propel the future of manufacturing and making the extraordinary possible.