The simplest tasks are often the biggest challenge. Many can program a microcontroller; not as many know how to make a simple actuated joint, a custom gearwheel, or a custom chassis for their creations. With 3D printers, we've been promised a revolution in desktop manufacturing, but many of the issues are more fundamental - having to do with mastering CAD software or understanding materials science to make lightweight and durable parts. Meanwhile, on the manufacturing side, a simple, affordable, and home-workshop-friendly solution - CNC machining coupled with resin casting - is already within reach.

This guide is more or less modular. If you're interested in buying a CNC mill, keep reading. If you already have one and know how it works, or want to try the overall process with a 3D printer or other manufacturing process, you can skip directly to the relevant part.

The Shapeoko is an open source CNC that you can either buy as a kit or build yourself for about $300us. Work up your design on a laptop using open source CAD software, clamp feedstock on the bed, and it'll produce what you designed. Because it's open source it's not limited to wood - it could be adapted to just about any material that you can cut or grind could be. Chances are, someone's already done it and posted the docs.

Everything is also kept in a respository on Github: https://github.com/shapeoko/shapeoko