Lego experiment

I was inspired by one of the Carbide 3D YouTube videos ( to try my own hand at making wooden Legos. I’m pretty happy with the results of my first attempt. It was a fun exercise and I’ve learned and picked up a few things about I have a few questions/observations.

  1. MeshCam will only make supports between the geometry and the stock,
    so to make the support between the lego pieces I had to add the
    supports to the model.
  2. There are two different roughing options, 3D and parallel path. I
    chose 3D, but for this model I would probably use parallel path like
    the Carbide 3D video.
  3. My roughing pass on the underside of the Legos never entered the
    interior of the Lego. I used an 1/8 inch bullnose bit for
    roughing. I assumed there was enough clearance inside the Lego to
    do the roughing pass and looking at the Carbide 3D it roughed out
    the interior. The end result was the finishing pass (1/6 inch
    bullnose bit) took out some rather large chucks of wood towards the
    end of the job.
  4. Figuring out the feeds and speeds was a challenge. I’m a novice, so
    I tried to use the MeshCAM auto toolpath feature, but jobs it
    produced would have taken days, so I downloaded a trial version of
    GWizard. GWizard already has the Nomad in it’s machine database
    which was a great help. I still have a lot to learn about stepover
    and plunge rates and feed rates, but I think it kept me out of the
    woods. I would tweak a value here and there and play with spindle
    speeds and GWizard would tell me if I was going to overload the
    motor or do something else bad. I think my stepover was somewhere
    around 30% so I believe that’s why there are scallops in the finish.
    I thought about making the stepover smaller, but as it was the top
    side took around 40 minutes to machine and the bottom side took
    around an hour. 80% of that was the finishing pass. I’d be curious
    to see what the Carbide guy’s used for their setting. Also, MeshCAM
    is supposed to have GWizard integration, but the copy and pasted
    didn’t work. Is that a feature of MeshCAM Pro?
  5. It looks like I didn’t get the registration holes straight down the
    middle of the stock. I think that’s why there is a slight shift in
    the Y-axis when I did the flip.


Those look nice! Are you planning on making a selection of bricks, or is this more for a decoration?

I might make some more. A small Lego set made out of wooden Legos would be a conversation piece.