Anodized Aluminum Pen

The pen tube blank you received is longer than the desired length. You will need to cut the tube to 5.00 inches (127mm) long. Use a sharpie and ruler to mark the aluminum tubing to the correct size. You will need to use a cut-off tool on the Dremel to cut the thin tubing. This tool can be found in the grey tool cabinet in the Learning Factory.

Once you cut any metal it is extremely important to de-burr your tube. A burr is a sharp edge formed by working metal. De-burring is completed with two tools. The first tool is located across from the table where the drill bits are kept. They are in the drawer labeled de-burring tools. You are looking for a Countersink De-burring tool. This will be used to de-burr the inside edges of the metal tubing. The Countersink is inserted into the end of the tubing and rotated clockwise to remove the burr. This should be done on both sides of the tube.

The next tool you will need is a File. This tool is in the back of the machine shop side of the Learning Factory. This tool is used to remove burrs from the outside of a part. They only cut in the push stroke. This means when you are holding the file on the edge of the part you are pushing the file from you; do not cut on the pull stroke, as this clogs and dulls the file. Rotate your part around as you file the edge, removing any sharp edges.

You will need to print all three parts. Follow the directions in the pdf below. You are welcome to modify these files or use your own.

3D Printing Instructions

3D Printing STL Files

You will need to create a file based on the measured dimensions of the pen cap that you just printed. It should look like the pen clip below. We have a wide variety of measuring tools available here at the Learning Factory. Measure the Pen cap to generate the correct dimensions you will require for a proper fitting pen clip. The Learning Factory staff has wood available for the pen clip. When you have your file complete, find a Learning Factory Staff Member, and we will help your laser cut your Pen Clip.

Please refer to the equipment page under Fab South equipment for information regarding the laser cutters!

You can use this image as an inspiration, but we encourage you to make your own design for the clip. You can even engrave your name on its side. We have a wide variety of measuring tools available here at the Learning Factory. Measure the “Pen Cap” to generate the correct dimensions you will require for a proper fitting “pen clip. The Learning Factory staff has wood available for the pen clip. When you have your file complete, find a Learning Factory Staff Member, and we will help your laser cut your Pen Clip.

Now that you have all your parts made you need to put them together.

1. The first step is to insert the “Pen Nose” into the “Pen Tube.”
2. Next, insert your “Ink Refill” into the “Pen Tube”. It will fit snugly into the “Pen Nose”.
3. Next, insert the “End Cap” into the Pen Tube”. You may want to shorten your “End Cap” for proper fit. Test fit the “End Cap” before gluing. Once it fits properly, you will have to place a small drop of super glue onto the face of the “End Cap” and glue it to the “Pen Tube” only. CAUTION: GLUING ANY OTHER PARTS TOGETHER WILL CAUSE THE INK REFILL TO BE IRREPARABLE.

Use this animation to help you visualize the pen assembly.

1. Next, place the “Pen Cap” onto the “Pen Nose”.
2. Next, check that the “Pen Clip” you made fits into the “Pen Cap” correctly. Some final sanding may be required for the best adhesion. Once test fitted, apply a small amount of the glue to the mating surface, and stick them together.