Project Overview

• Project Name 2026 Wood & Aluminum Industrial Perpetual Calendar
• Equipment HiMill D1S Desktop CNC
• Core Challenge Aluminum cutting (rigidity & cooling test)
• Key Features Minimalist style, Brushed texture, Everlasting
• Main Materials Walnut & 3mm 6061 Aluminum Alloy

Preparation

Since we are dealing with "hard-on-hard" machining, material selection and tooling are critical.

Hardware Materials (BOM)

• Aluminum Sheet: 6061 Aluminum is highly recommended (excellent machinability, less "gummy"), 3mm thickness.
• Wood: A dark hardwood like Walnut is ideal to contrast the silver sheen of the aluminum.
• Cooling/Lubricant: Alcohol spray bottle or cutting fluid is mandatory to prevent material welding to the bit.

Recommended Tooling (Aluminum Specific)

Never use a standard 2-flute straight bit for aluminum—it will snap!

• The Secret Weapon: Single Flute Spiral End Mill.
• Why: It provides a large chip clearance area, allowing aluminum chips to be ejected rapidly. Recommended diameter: 3.175mm or 2mm.
• Wood Engraving: Laser module.

CAM Programming Strategy

Machining aluminum is entirely different from wood. The golden rule is: "Slow feed, thin passes."

Step 2.1 Aluminum Slider Settings

To ensure a mirror-like finish on the edges, use these conservative parameters:

• Spindle Speed: 13,000 RPM
• Feed Rate: 200 mm/min
• Step Down: 0.1mm - 0.2mm (CRITICAL!)

Step 2.2 Tolerance Fit

Unlike wood, aluminum has zero elasticity. The fit must be exact. In the design phase, I applied a -0.1mm negative tolerance to the aluminum slider.

CNC Machining Process

The HiMill D1S’s time to shine!

1. Wood Processing: Easily handle the digital engraving and outer contour of the Walnut backplate.
2. Aluminum Processing (The Main Event):
   • Clamping: Secure the sheet tightly using pressure plates and double-sided tape.
   • Lubrication: Spray alcohol every few dozen seconds during the cut.
   • Observation: The Z-axis of the HiMill D1S remains rock steady, producing holes with perfect circularity.

Post-Processing: The Brushed Look

1. Deburring: Use a deburring tool or fine file to remove sharp aluminum slivers.
2. Brushed Finish: Rub the surface repeatedly in a single horizontal direction using a Scotch-Brite pad or 400-grit sandpaper. This creates that high-end "MacBook" texture.
3. Oiling: Apply wood wax oil to the Walnut to deepen its tone and bring out the grain.

Assembly & Summary

When the silver brushed aluminum is embedded into the deep walnut grooves, the contrast is stunning. The slider moves smoothly, and the circles align perfectly with the numbers.

Summary: This project proves that the HiMill D1S is fully capable of light metal fabrication. With the right parameters, you can create professional-grade metal crafts at home!