Carbonite Compactor
Interchangeable-Insert Aluminum Ice Press
Product Design & CNC Manufacturing
Role
Product Designer & CNC Machinist
Team
Individual engineering project
Sponsor
Stanford Product Design Lab
Tools
Fusion 360, CNC machining, probing, 3D printing
The Challenge
Large cocktail ice can be difficult to produce with limited freezer space and standard ice trays. The press needed enough thermal mass to shape the ice while maintaining precise alignment and a close fit between its machined components.
The Solution
I designed and manufactured a two-piece aluminum ice press with interchangeable CNC-machined inserts. Two press-fit steel dowels align the upper and lower shells, while removable inserts allow the press to create multiple ice-cube designs.
My Contribution
I took the project form ideation, CAD, prototyping, CNC process planning, machining, and assembly.
Design
Developed the two-piece press architecture, alignment system, and interchangeable insert geometry.
Machine
Planned the CNC operations, work coordinate systems, toolpaths, part flips, and workholding strategy.
Assemble
Reamed the alignment holes, installed the steel dowels with an arbor press, and validated the final component fits.
Design, Build & Test
CAD assembly of the ice press detailing the inserts and how they are fit into each half.
Prototyped press fitting tolerancing with scrap aluminum. Concluded a 0.001” difference in diameter would cause a slip fit sufficient for the ice press.
Used 2″ shell mill, 1/2″ flat end mill, 1/2″ ball end mill, and an engraver for the outer shells. Required two work coordinate systems.
Used 1/2″ FEM, 1/4″ FEM, 3/16″ BEM, and 2″ shell for the inserts. Required two work coordinate systems.
Efficient Manufacturing Strategies
A consistent back-left-lower datum and multiple work coordinate systems enabled accurate part flips.
Double parallels and newly machined vertical walls provided secure clamping access for later insert operations.
Reused and repurposed multiple tools to minimize set up and clean up time.
Results
6+ Hours
Run Time on the CNC
6+ Hours
Set Up and Clean Up Time
Success
Ice Press is Functional