This project was carried out during my industrial internship at PT Pupuk Kalimantan Timur between October 2024 – January 2025. The focus of the project was the design and manufacture of a custom CNC milling workholding fixture, known as the Ignite Clamp, to support maintenance workshop operations.

The Ignite Clamp was developed to improve machining efficiency and setup time, particularly when handling complex or non-standard parts. By applying a side-clamping mechanism, the fixture allows faster workpiece positioning compared to conventional clamping methods, making it more suitable for repetitive maintenance tasks.

My Specific Contributions

Design Phase
I designed the Ignite Clamp using SOLIDWORKS, creating detailed 3D models and complete engineering drawings. The design process emphasized achieving sufficient clamping force, maintaining rigidity during machining, and ensuring compatibility with existing CNC milling tables used in the workshop.

CAM Programming
I generated optimized toolpaths and G-code using Mastercam, selecting machining strategies that prioritized safety, efficiency, and dimensional accuracy. Considerations included tool selection, cutting parameters, and collision avoidance.

Production & Assembly
I operated CNC Milling machines to manufacture the fixture from raw material through final assembly. Throughout the production process, I ensured high dimensional accuracy and validated the functionality of the clamp during trial machining.

Learning Outcomes

Through this internship project, I gained hands-on experience in translating digital designs into real shop-floor solutions. The Ignite Clamp demonstrates how fixture design directly influences machining efficiency, reinforcing my understanding of the full workflow from CAD and CAM to manufacturing execution in an industrial environment.