The shallow mouth opening has too steep of an angle and tends to peal the cap back. The mouth opening was elongated to give better leverage to lift the cap.

During the initial prodcution machining, the machining speed and feed parameters used during prototyping was slowly increased. Gradually, the machine time per bottle opener was reduced from18 minutes to 15 minutes. The vibratory deburing took another 4 hours and tumble burnishing takes around 2 hours. The logo engraving process takes another 5 minutes.

The mouth lip was modified for better clearance and the center cavity was removed to help speed up the machining process and the logo were modified to reflect the coarser resolution of electrochemical etching. The height was also reduce to better fit the raw stock height.

An electrochemical etcher was used to explore using etching the Tux-Lab logo on to the Stainless Steel bottle opener.

Tumbling with the ceramic media on the left will deburr and slightly round the sharp edges. Burnishing with the porcelain media on the right will brighten the surface dulled by the deburring process.

Before the g-code can be written, the transition points for the machining tool path needs to be determined. In g-code, the tool path is represented by a series of linear and circular moves. Each transition point, ie where straight line meets a curve or where curves of different radius meets, needs to be specified in terms of its X-axis and Y-axis coordinate.

The effect of hollowing out the bottle opener was explored with Z88Auora,  the GUI version of Z88, an open source FEA software.  The ascii mesh was created using FreeCAD and imported into Z88.

A dxf file was exported from FreeCAD and imported into LibreCAD for dimensioning the endpoints for writing g-code. Since the current version of FreeCAD, v0.12, is millimeter only, a reduction factor of 25.4 was applied to the imported dxf file to derive the measurements in inch.