The Metal Shop is captain by Chris Santacroce

1. Members must have completed MAKE Roanoke’s new member orientation before using the Metal Shop.
2. Digital calipers, scales, files, and other simple hand tools are considered Green tools. Use of these tools requires completion of general space, and shop-specific orientations.
3. Micrometers, indicators, and other precision metrology equipment are considered Yellow tools, due to the delicate nature of said equipment, and knowledge requirements for use. Tool-specific competency training must be completed prior to use.
4. All machines in the Metal Shop are considered Red tools. Tool-specific competency & safetytraining must be completed prior to use.
5. Food or drinks are strictly prohibited in the shop.
6. Do not leave chuck keys in the chucks.
7. All files must have handles.
8. Do not take measurements with the machine running.
9. Do not walk away from a running machine.
10. Make sure the machine is stopped before changing speeds/gears/etc..
11. Machines must be allowed to spin down on their own. DO NOT slow/stop a spindle with your hand.
12. Do not clear chips with your hands. Use a brush, tweezers, pliers, or another suitable tool.
13. Do not use compressed air to clear chips from machines, yourself, or others.
14. No mist coolant allowed.
15. Do not attempt to use dull or damaged cutting tools. Place all unusable cutters and inserts in the appropriate container.
16. Long hair must be tied back in such a manner, as to keep it behind your shoulders.
17. Necklaces, hood strings, and the like must be tucked into your shirt, or removed.
18. The following clothing/items are not allowed under any circumstances:
    1. Long sleeves
    2. Rings
    3. Watches
    4. Gloves of any kind, including latex/nitrile gloves.
19. Unless performing an operation that requires hearing protection, you must have at least one ear open. Having earbuds in both ears is prohibited.
20. Materials placed in the scrap bin must be deburred.
21. The bench grinder is for ferrous materials only (steel, iron). Grinding soft materials such as aluminum, brass, or plastic can clog the wheel, resulting in a potentially dangerous condition.

1. Clean up after yourself.
2. Mark raw materials whenever possible:
   1. Type of material
   2. Alloy
   3. Heat Treat, if applicable
3. If a piece of material is marked, cut your stock off the end opposite the mark.
4. Do not machine wood or fiberglass.
5. Do not use grinding equipment of any kind on workpieces in machines.
6. Cover or otherwise protect machine ways/slides when cutting hard materials (i.e., hardened steel).
7. Avoid the use of excessively smoky cutting fluids. Use correct PPE as appropriate.
8. Return machines to their default state when you’re finished. Some examples:
   1. If you removed the vise from the mill, put it back and tram it in.
   2. If you set-over the tailstock on the lathe, re-center it.
   3. If you tilted/nodded the mill head, tram it back in.
9. Keep measuring equipment clean, and put away when not in use.
10. Keep the surface plate covered when not in use.
11. Be mindful of others. Do not monopolize machines, and do not touch other’s projects.
12. Do not leave projects on machines when you’re done for the day. The use of fixture plates, sub-vises, and other methods of quickly restoring a setup, is encouraged.
13. Storage of in-progress projects subject to space restrictions and Parking Permit rules, unless otherwise approved by the Shop Captain.
14. If you suspect a measuring instrument is inaccurate or requires calibration, label the instrument as suspect, and inform the Shop Captain.

• Milling Machine: Bridgeport Series 1 (round ram, M-head)
• Bandsaw: Delta 28-560
• Mini Lathe (7×16)
• Green Instruments Pantograph engraver

• Granite surface plate (36“x36”)
• Height gauge

• Bench grinder
• Drill bit sharpener

General

1. Check chuck key removal before starting
2. Secure workpiece properly
3. Remove chips with brush or vacuum only
4. Never leave chuck key in chuck

Before Use:

1. Oil all ways and sliding surfaces
2. Verify smooth carriage movement
3. Ensure chuck key is not in chuck

After Use:

1. Wipe down all surfaces
2. Remove all chips
3. Clean and store any tools used
   • Especially the chuck key.

Lathe Maintenance

• Weekly:

1. Clean and inspect chuck jaws
2. Check belt condition
3. Clean and oil change gears

• Monthly:

1. Inspect electrical cables
2. Clean and adjust gibs if needed
3. Check tailstock alignment
4. Level machine

General

Verify the pantograph ratio settings match your project requirements Secure the master template firmly to the template table Mark reference points on blanks for alignment Select appropriate holding fixtures for your workpiece Secure the workpiece firmly to prevent movement during engraving Ensure the workpiece surface is perpendicular to the cutting tool Adjust depth settings in small increments Test depth settings on similar material before final engraving Consider multiple passes for deeper engravings

Before Use

1. Choose the appropriate cutter type based on material:
   • Carbide for metals and hard plastics
   • High-speed steel for softer materials
   • Diamond-tipped for glass or stone
2. Select the proper cutting angle for your material
3. Verify cutter sharpness before starting
4. Set the correct depth of cut for your application

After Use

1. Clean machine after each use
2. Remove all chips and debris
3. Wipe down surfaces

Maintenance

• Daily

1. Check for loose components
2. Check belt for condition and tension

• Monthly

1. Lubricate moving parts according to manufacturer specifications
2. Check and tighten all fasteners
3. Inspect stylus and cutters for wear

Handling and Storage

1. Handle all measuring instruments with care to prevent damage
2. Store instruments in protective cases when not in use
3. Maintain a clean environment for storage
4. Keep instruments away from moisture, dust, and extreme temperatures

Usage

1. Select the appropriate instrument for the measurement task
2. Clean measuring surfaces before and after use
3. Follow manufacturer's operating instructions
4. Apply consistent measuring force when using contact instruments
5. Allow temperature stabilization between instrument and part
6. Take multiple measurements for verification
7. Report inaccurate or out-of-calibration equipment to Shop Captain.

Maintenance

1. Perform regular visual inspections for damage or wear
2. Clean instruments according to manufacturer recommendations
3. Lubricate moving parts as specified
4. Check batteries and power supplies regularly
5. Verify zero settings before measurements
6. Perform periodic performance checks between calibrations