Jeremy Fielding

Machining Parts for Wall-E. Episode 03

The video documents the third episode of a DIY series in which the creator fabricates the tracks for a life‑size, functional Wall‑E robot. Starting with a salvaged 1‑inch aluminum plate, he outlines the plan to machine, weld, and assemble the components, while also 3D‑printing resin hubs and tread pieces that will fit inside Wall‑E’s compact body. Key technical steps include improvising a circular saw to cut the oversized metal, using a combination drill‑tap to manually tap holes, and printing custom drilling jigs in fast‑cure resin to ensure precise hole placement. The maker runs multiple CNC programs, tests coolant settings, and switches between fast resin and tougher Formlabs Tough 1000 to balance support density and part strength. Repeated “heat” warnings and X‑axis travel errors illustrate the trial‑and‑error nature of low‑volume manufacturing. Notable moments feature the creator’s candid commentary—"Heat. Heat. Heat."—and his decision to air‑cut every program after a series of crashes. He highlights a partnership with PCB Way for lathe‑specific parts, praising their ability to produce large resin prints, sheet‑metal, and injection‑molded components that exceed his shop’s capabilities. The footage also shows the contrast between coolant‑obscured cuts and a dry run to capture cleaner video. The episode underscores the practical challenges small‑scale fabricators face when translating cinematic designs into functional hardware. It demonstrates how makers blend traditional machining, additive manufacturing, and outsourced services to overcome equipment limits, offering a roadmap for hobbyists and startups aiming to prototype complex electromechanical systems.