Make & Learn
In 2019, while interning at Nokia, I set out to
understand what it really takes to build a
product from scratch. I chose a kitchen scale as
a case study. I ordered a simple scale, took it
apart, and used its internal components as the
foundation for my own design.
The goal was not just to redesign the object,
but to learn through making. I wanted to explore
CNC machining in aluminum, experiment with
achieving a true mirror-polished finish, and
understand how individual parts come together
into a functioning product.
In 2019, while interning at Nokia, I set out to understand what it really takes to build a product from scratch. I chose a kitchen scale as a case study. I ordered a simple scale, took it apart, and used its internal components as the foundation for my own design.
The goal was not just to redesign the object, but to learn through making. I wanted to explore CNC machining in aluminum, experiment with achieving a true mirror-polished finish, and understand how individual parts come together into a functioning product.
Material & Finsih Studies
Throughout the process, I continuously tested
materials and surface treatments to achieve the
desired look and performance. For the acrylic top,
I explored laser engraving, sandblasting, and sanding
to create a matte, more scratch-resistant surface.
While each method altered the finish, none delivered
the clarity and quality I was aiming for. Ultimately,
I chose a glossy surface balancing durability with
improved display readability.
A four-section mold places parting lines
within the highlights of rounded surfaces,
rendering them invisible in typical viewing
conditions. The mold split allows for zero-degree draft angles on exterior surfaces preserve geometric purity. The result is crisp surfacing that reflects the design intent.
Aluminum Machining
The bottom half of the scale is machined from aluminum.
A key objective of the project was to learn how to work
with this material hands-on—understanding not just the
design, but the process behind making it.Programming
and setting up the CNC machine became an essential
part of that journey, offering valuable insight into
machining constraints, toolpaths, and the translation
from digital model to physical part.
The Beacon 2 relies on passive convection
cooling, requiring continuous airflow through the enclosure to dissipate heat from the internal heatsink. Alongside antenna clearance, thermal management became one of the primary drivers in
the design process. The challenge was to integrate sufficient ventilation area while maintaining the calm, minimal appearance that defines the product.
The bottom half of the scale is machined
from aluminum. A key objective of the
project was to learn how to work with this
material hands-on—understanding not just
the design, but the process behind making it.
Programming and setting up the CNC machine
became an essential part of that journey,
offering valuable insight into machining
constraints, toolpaths, and the translation
from digital model to physical part.
Refining the Surface
Creating a true mirror finish on the aluminum surface proved
to be one of the more challenging aspects of the project.
The relatively soft aluminum made it difficult to achieve a
consistent, high-quality finish without introducing imperfections.
I explored a range of techniques from progressive sanding
and polishing to different surface treatments—iterating until the
desired result was reached. At the same time, the limitations of
the CNC process became apparent, as visible tool paths had to
be carefully removed through post-processing.
The Beacon 2 relies on passive convection
cooling, requiring continuous airflow through the enclosure to dissipate heat from the internal heatsink. Alongside antenna clearance, thermal management became one of the primary drivers in
the design process. The challenge was to integrate sufficient ventilation area while maintaining the calm, minimal appearance that defines the product.
Creating a true mirror finish on the
aluminum surface proved to be one
of the more challenging aspects of
the project. The relatively soft
aluminum made it difficult to achieve
a consistent, high-quality finish without
introducing imperfections. I explored a
range of techniques from progressive
sanding and polishing to different surface
treatments—iterating until the desired
result was reached. At the same time,
the limitations of the CNC process
became apparent, as visible tool paths
had to be carefully removed through
post-processing.
Final Assembly
The internal structure was built using 3D-printed components,
designed to precisely locate and secure all parts from the
original scale. These custom parts integrate the necessary
features to hold the electronics in place and align them within
the new enclosure.To make everything work within the
redesigned form, parts of the electronics had to be resoldered
and rewired. Threads were cut directly into the aluminum housing,
allowing all internal components to be securely assembled without
introducing external fasteners.
This final stage brought together all elements of the project:
mechanical, electrical, and material—into a fully functioning product.
The Beacon 2 relies on passive convection
cooling, requiring continuous airflow through the enclosure to dissipate heat from the internal heatsink. Alongside antenna clearance, thermal management became one of the primary drivers in
the design process. The challenge was to integrate sufficient ventilation area while maintaining the calm, minimal appearance that defines the product.
The internal structure was built using
3D-printed components, designed to
precisely locate and secure all parts
from the original scale. These custom
parts integrate the necessary features
to hold the electronics in place and align
them within the new enclosure.To make
everything work within the redesigned form,
parts of the electronics had to be resoldered
and rewired. Threads were cut directly into
the aluminum housing, allowing all internal
components to be securely assembled without
introducing external fasteners.
This final stage brought together all elements
of the project: mechanical, electrical, and material
into a fully functioning product.
