← All projects

Wilbur's Design Labs, Lehigh University · 2024–2026

Project Specialist
Gallery

Parts Designer & Fabrication Lead

Wilbur's Design Labs is Lehigh's maker space — a wood and metal shop open to every student on campus. The Art, Architecture and Design department used it most, so most of my work went to them. The brief was rarely an engineering drawing; usually a description, a deadline, and a budget. Choosing the process was most of the job.

Machining & CNC

Programming and running parts across CNC milling, plasma, and laser. Material and process were chosen per job: aluminum and steel where the part carried load, acrylic where it had to be seen through, sheet where speed mattered more than tolerance.

CAM toolpath programming on a laptop beside the machine
Toolpath programming
Aluminum part being machined on a Tormach CNC mill under coolant
Aluminum on the CNC mill
Aluminum part being machined on the CNC mill under coolant
Aluminum under coolant
CNC plasma table cutting sheet steel
CNC plasma cutting
Laser cutter running a job
Laser cutting
Engineering drawing of the Stromberg UU-2 carburetor spacer with dimensions and title block
Carb spacer drawing
3D-printed reference part used to check fit before machining
3D-printed reference, test fit
The metal shop where the work was made
The shop

Metalwork & Design Objects

Commissioned pieces where the requirement was as much visual as structural. These came mostly through the AAD department, where the customer specified an intent rather than a dimension and I worked backward to something buildable.

The lamp started in CAD and came out of four different processes. The perforated fascia was waterjet cut from a file I generated off the model, and it holds onto the body magnetically rather than by fasteners, so it lifts straight off. The body itself is fully TIG welded steel. The diffuser is acrylic, laser cut to size and then clouded with heat to scatter the light instead of leaving the bulb visible through it.

The side table is a cantilevered steel frame with an integrated planter. The finish is the point: black paint eaten back to a deliberate rust patina, with the shell pierced through so it reads like a rotted-out car body panel. The blade blanks were waterjet cut from a hardened cobalt steel metal-cutting saw blade that had broken. The material was already the right alloy for an edge, so instead of scrapping it I nested five knife profiles inside the disc — two chef blades, two utility, and a paring knife — and cut the set out of what was left.

CAD model of the curved lamp shell showing the slot pattern
Lamp, CAD model
Waterjet cut file for the lamp fascia, slot pattern laid out flat
Waterjet cut file
The finished TIG welded steel lamp with the perforated fascia in place
Built, fascia on
Cantilevered steel side table with integrated planter, black paint over a deliberate rust patina and pierced holes
Cantilevered side table
Waterjet nesting drawing showing five knife profiles laid out inside a circular saw blade
Waterjet nest in saw blade
Knife blanks waterjet cut from a broken cobalt steel saw blade
Blanks from a cobalt blade

Woodworking

Furniture and smaller commissioned pieces. Process was matched to purpose — hand-tooled where the piece was a gift, CNC where it was a production run, mixed where a build needed both.

Live-edge river table

A live-edge slab with a poured epoxy river running the length of it, the natural edges left intact on both sides.

Live-edge river table with blue epoxy pour
Live-edge river table

Tensegrity side table

The odd one out: the oak top does not rest on the base at all. It is held in tension by cables, so the structure carries load through a path that looks impossible until you find the wires. Modeled first, then built.

Tensegrity side table, oak top suspended on tension cables above a curved steel base
Tensegrity table, built
CAD model of the tensegrity table showing the curved tube geometry
The CAD model

Padauk jewelry box

CNC machined from padauk, a dense hardwood that finishes to a deep red. Brass feet and a brass latch, with the ring section lined in velvet and the main compartment left as bare finished wood.

Padauk jewelry box closed, showing the brass latch and feet
Padauk jewelry box
Jewelry box open, showing the velvet-lined ring slots and open compartment
Velvet-lined ring slots

Walnut cigar box

The most process-heavy thing here. It is machined from a single piece of walnut on a manual mill, cut to measurements taken off a CAD model I built first — pockets for the cigars, a recessed rest, and a sliding lid. The lid is laser engraved from a vector path I drew in Photoshop, and the inside is lined with leather to hold humidity and protect what is stored in it. First time doing leatherwork.

Walnut cigar box closed, with the sliding lid laser engraved LITCHFIELD
Walnut cigar box, closed
Cigar box open with the engraved sliding lid removed, showing the milled pockets
Lid off, pockets milled
Angled view of the cigar box showing the recessed cigar rest machined into the walnut
Machined from one piece