DIY Aluminum Caliper: a Complete Guide to Manufacturing

A caliper is one of the most important tools for precise measurements. Today, I will share how I created my own custom aluminum caliper. I will walk you through the process of designing a 3D model, explain why I chose JLCCNC for manufacturing, demonstrate the assembly, and discuss an important detail—aluminum anodizing.

Here you can watch a video where I used and demonstrated a homemade caliper. You can see it in action at the 02:00 minute mark. https://youtu.be/jAHd84BQ-xc?si=riNgKn4UZ6d3AFx4&t=133

A Bit of History and Interesting Facts

The caliper was invented in the 17th century, but primitive versions of this tool existed much earlier. In 1631, the French scientist Pierre Vernier developed an additional scale (the vernier), which allowed measurements with an accuracy of up to hundredths of a millimeter. Today, this tool is widely used in mechanical engineering, aerospace, jewelry making, and many other fields.

Interesting fact: In Ancient Rome and China, archaeologists have discovered metal tools resembling modern calipers. This suggests that people have been using similar measuring instruments for thousands of years!

Another fun fact: The world's largest caliper was created in Germany and measured approximately 2.5 meters in length!

All we need to create a caliper is our imagination and the desire to design a unique and innovative 3D project tailored to any requirements. As for high-quality materials and precision machines, we won’t need them since we’ll be ordering the manufacturing from JLCCNC.

JLCCNC is a platform providing high-quality and precise mechanical part manufacturing services. The company uses modern technologies such as milling and turning, laser cutting, and other types of mechanical processing. On the website, you can order both prototyping and small-batch or mass production.

The main advantage of JLCCNC is the ability to order parts with high precision according to individual requirements, using advanced equipment and high-quality materials. They offer a transparent ordering process with convenient cost and lead time calculations, making their solution accessible and efficient for any project.

Go to https://jlccnc.com/?from=ruhcnc2 and get $60 new user coupons for all your custom manufacturing needs, starting at just $1.

#JLCCNC

I have attached two files here. You can modify them, refine them, and make them slightly smaller or larger depending on your needs. I have a small caliper, but now I need a larger one.

Where to Order and Download the 3D Model

If you want to replicate this project, here are the links:

1. Download the 3D model:
2. Order manufacturing at JLCCNC: (link)

After that, I placed an order for the parts. I tested several options but encountered some issues:

1. One website promised to provide a price estimate within 24 hours but never responded.
2. Another service quoted €400 for just one part!

In the end, I chose JLCCNC, where I was able to order high-quality parts at a great price.

Aluminum anodizing is a process in which a protective oxide layer forms on the surface. This layer can be 5-8 microns thick. It increases corrosion resistance and enhances the appearance of the metal, but there's a catch: the layer can affect the precision of fitting parts together.

I overlooked this and faced a problem—one of the moving parts didn’t fit properly. I had to use a file to remove the excess anodized layer from the inner part to ensure smooth movement.

Additionally, I selected anodizing with a glossy finish for one part and a matte finish for another. I was really curious to see the difference and wanted to demonstrate it to you so you can understand the distinction between matte and glossy aluminum anodizing. This can be a crucial factor when choosing the appearance and texture of your parts.

Laser Engraving the Scale

On the JLCCNC website, you can upload a 2D file with the scale markings, and they can laser engrave it onto the main caliper part. However, I decided not to do this because I want to experiment with high-precision engraving at home. If you prefer a fully finished tool, you can prepare the scale in advance and order laser engraving.

Alternative Design Option

If you want to make the tool even more versatile, you can create a slot to insert a metal ruler. This way, you get a two-in-one tool—a caliper and a standard linear measuring instrument.

Once I received the parts from JLCCNC, I started the assembly process. It took very little time, and the final result exceeded my expectations! Here are some photos of the assembly process:

The caliper turned out to be precise, convenient, and fully aligned with my design.

I highly recommend ordering from JLCCNC because they offer excellent quality at reasonable prices. I hope you enjoy this project!