Fabrication Tools and Safety

Core tools#

• Bandsaw (horizontal/vertical) — cuts tube and plate to length with a continuous blade. Use a metal-cutting blade for metal and a wood blade for wood — the wrong blade snaps, burns, or grabs. The single most-used cutting tool for tube.
• Drill press — drills accurate, square holes in stock too big or precise for a hand drill. Clamp the work; never hold it by hand.
• Mill (manual or CNC) — a rotating cutter removes material to make precise features, pockets, and holes; the vertical mill's spindle moves up/down while the table moves in X/Y.
• Lathe — spins the workpiece against a fixed tool to make round parts: shafts, spacers, standoffs, custom pulleys.
• CNC router — a 3-axis machine that cuts wood, plastic, and aluminum plate; the most powerful affordable way for teams to produce custom plates and gussets directly from a CAD file.
• Hand tools — drill/driver, taps and a tap handle, files and a deburring tool, calipers, and a full set of hex keys and nut drivers.

Tapping threads#

To make threads in a hole, drill the correct tap drill size first, then run a tap in straight, backing off frequently to clear chips and using cutting fluid on aluminum. Thin aluminum strips threads easily, so prefer a nut on the back side when material is thin.

Finishing#

Always deburr cut edges and drilled holes — burrs cut hands, prevent flush mating, and concentrate stress. A quick chamfer or pass with a deburring tool is worth it.

Safety (non-negotiable)#

FIRST publishes Tool & Fabrication Expectations, and good shops enforce:

• Eye protection always in the shop — safety glasses/goggles that are ANSI-approved, UL Listed, CE EN166-rated, AS/NZS-certified, or CSA-rated (per the FIRST Safety Manual); plus closed-toe shoes; no loose clothing, gloves around rotating tools, dangling jewelry, or untied long hair.
• Training before use. Power tools like the drill press, bandsaw, mill, and lathe are dangerous and require sign-off by a trained mentor.
• Clamp the work, keep hands away from blades/cutters, and never leave a machine running unattended.
• Know where the E-stop / power switch and first-aid kit are.

A fast team is a safe team: injuries and rushed mistakes cost far more time than doing it right.