Creating a DIY Mallet With Phone Holder and Thumb Indentation in Vectric Aspire

In this Instructable, I'll guide you through the process of creating a custom mallet with a unique twist. By partnering with Vectric and utilising their Aspire software, we'll design a mallet that features a convenient slot for holding your phone and a comfortable thumb indentation for precise carving tasks. This project combines the power of CNC machining with traditional woodworking techniques, resulting in a practical and ergonomic tool. So, let's dive into the steps and bring this innovative mallet to life!

• Two types of contrasting hardwood
• A CNC machine
• Vectric Aspire software

The file for my mallet is available for download from :

https://www.vectric.com/vectric-community/free-projects/partner-projects/DeanMakesMakersMallet

In this step, we'll use Vectric Aspire software to design a unique mallet with special features. The mallet will include a slot that acts as a phone holder and an indentation for your thumb, providing comfort during fine carving tasks.

Start by opening Vectric Aspire and experiment with different shapes and dimensions to create your desired mallet design. Use the software's tools and features to precisely define the slot and thumb indentation.

For this project, we'll use padauk and maple as our materials of choice. Here are the specific dimensions and thicknesses required:

• 2 Boards of Padauk: 150 x 100 x 20 and 300 x 100 x 25
• Maple: 100 x 250 x 20

These hardwoods are excellent choices for striking tools. If you prefer other options, consider hardwoods like oak, beech, or walnut. Ensure the selected materials are sturdy enough to withstand the impact of striking.

In this step, we'll securely attach the chosen materials to the bed of our CNC machine to begin the carving process.

1. Clean the surface of the CNC machine bed to ensure proper adhesion.
2. Place the materials on the bed and align them according to your design.
3. To secure the materials, you have several options:

• Method 1: Painter's Tape and Super Glue (Recommended)
• Apply strips of painter's tape across the edges of the materials, ensuring they are firmly attached to the bed. The tape provides initial stability.
• Apply a thin layer of super glue to the back of the materials, focusing on the areas where the tape is placed. Press the materials firmly onto the bed to create a strong bond. The super glue enhances the adhesion and prevents any movement during carving.
• Method 2: Clamps
• Use clamps specifically designed for CNC workholding to secure the materials to the bed. Position the clamps strategically to hold the materials firmly in place. This method is particularly useful when working with thicker or heavier materials.
• Method 3: Double-Sided Tape
• Apply double-sided tape to the back of the materials, ensuring complete coverage.
• Press the materials onto the bed firmly, making sure they are aligned correctly. The tape provides a strong temporary bond during the carving process.
• Method 4: Vacuum Workholding
• If your CNC machine has a vacuum workholding system, use it to hold the materials securely in place. This method utilizes suction to grip the materials, allowing for efficient and reliable workholding.

Choose the method that best suits your CNC machine, the size and weight of your materials, and the complexity of the carving process. Ensure stability and security during the entire machining operation.

Now, it's time to assemble the mallet components and create a sturdy structure.

1. Apply regular wood glue to the appropriate surfaces of the mallet components.
2. Align the pieces accurately and use 4mm dowels to reinforce the joints. Insert the dowels into pre-drilled holes, ensuring a snug fit.
3. Clamp the components together to apply pressure and allow the glue to dry.
4. As an additional measure, create a wedge from the same material or a contrasting wood. This wedge will be driven into the handle to secure it firmly in place.

Allow the glue to dry completely before proceeding to the final step.

Congratulations on successfully creating your custom mallet with unique features!

I hope this instructable has inspired you to explore your creativity and craft your own personalized mallet. Feel free to experiment with different materials, shapes, and features to make it truly yours.

Happy crafting, and don't forget to share your results and experiences in the comments section below the video!