Making an Aluminum Hanukkah Menorah
This Hanukkah, I made a menorah using Plethora’s manufacturing system.
![](/images/318cc1847d402693c5d339fa72ae813cce6e51fceec985eca2266355511d1cfe.jpg)
Designing the Part
I started by designing the menorah using OnShape – a free, browser based CAD program. OnShape is super easy to use and it can export files in many formats. Usually I’d use SolidWorks with the Plethora Add-in, but my Windows remote desktop was down. The Add-in gives instant manufacturability, price, and ordering feedback and it also works with Autodesk Inventor.
![image](/images/d0c9c1cebb4d1a1a038438281fe2b95f7337985fecdf9e3c36d60adbace72171.png)
I’ve made the final part file public and you’re free to copy and remix it.
After designing the part, I downloaded the file and opened it in a coworker’s copy of SolidWorks. I ran it through the Plethora Add-in and found out that my fillets (the rounded corners) were too tight on the inside for the depth of the part – the mill wouldn’t be able to reach all the way through. I quickly increased the fillet radius slightly reduced the depth of the part. The menorah then passed the Add-in and I got an instant price quote and placed an order.
I didn’t have to pay (perk of working at Plethora) but if you want to make one, it should cost about ~$140 depending on the ship date. That’s well within the free credit ($250) you get when you sign up.
Milling the Menorah
Since our office is in the factory, I got to watch the part get made.
The first step is cutting the stock – we used 6061 Aluminum (what most aluminum products are made from).
![image](/images/8e20de38a87a3eab847554b6fc334b2fae0eaf5fa584bb81ed9aa6dbab1daab1.jpg)
Next, we loaded the stock into a 5-axis CNC Milling machine. We used a 5-axis machine so we could rotate the part to drill the candle holes. In this shot, the machine is probing the aluminum stock to locate it precisely.
![image](/images/776939d82f135b7bcfbf2ea9c6b58c444795cfcdb894efc990e4f802ee8c8e31.jpg)
Once the milling starts, coolant and aluminum swarf (chips) fly everywhere and it’s tough to get a good photo. This next shot is from partway through the process and you can see the basic shape taking form.
![image](/images/88576b4b36b45257b68f542255e6f75898afdc9ef0655d6a20604e02eea5e4c4.jpg)
After milling the front of the Menorah, the machine’s bed tilts 90 degrees so we can drill candle holes in the top. If we were using a 3-axis machine, we’d have to take the part out and create work-holdings for it. In this next photo, the spot drill is creating the initial candle holes.
![image](/images/900b1f1216537bf1d82ff38c67d8272234f3a2aed56cceedad065c604f2144e8.jpg)
Here’s the menorah partway through the manufacturing process:
![image](/images/2c1a980d5d3f5df244694fee3d56a58b23db4b8d092f84b0fc15b6fda9121146.jpg)
The remaining step is to remove the “raft” at the bottom of the part and face it for a smooth finish. Here’s the part fresh out of the machine at the end of the process:
![image](/images/e2295d43356fa5cc66c4a9fb00f75236523aff6d090c9c34d222e59185195256.jpg)
Shiny! I could have stopped here but decided to media-blast it for a matte finish. This process makes it look a bit like a Macbook.
![image](/images/9f16734ceb1c42b43118c64d197e45af15e8b1021c4fb67c556b8d3d24eb675f.jpg)
I’m extremely happy with how it turned out! Big thanks to Aly Kaderali and Michael von Sothen their help throughout the process!
Here’s a final picture of me lighting the candles, which fit perfectly in the menorah:
![](/images/f590ef2ace9773c16edf2228690b7df805fb5cdc573cb1f76e0f7ecb6e49472e.jpg)