What is this CNC milling machine?

A CNC milling machine designed and built from scratch by Ewan Wills, a UK-based product designer with a robotics engineering background. It is intended for aluminium machining, and the design work focused on mechanical accuracy, structural rigidity, and motion control.

Can a DIY CNC mill really cut aluminium?

Yes — provided the machine is designed for it. Cutting aluminium demands structural rigidity (to resist deflection under cutting load) and precise motion control. Those two requirements drove this machine's frame and drivetrain design. A demonstration video of the machine is linked from this page.

Who builds custom CNC and motion-control machines in the UK?

Ewan Wills is a UK-based freelance product designer who designs custom motion systems, gantries, and machine tools as part of an end-to-end product development service — from concept and prototype through design for manufacture to supplier handoff.

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Case study · By Ewan Wills, freelance product designer · UK · Last updated 2026-07-03

Machine tool · Personal project · Doc EW-CS-02

CNC mill, from scratch.

A CNC milling machine designed and built from scratch for aluminium machining. The design centres on the three things that decide whether a DIY mill can genuinely cut metal: mechanical accuracy, structural rigidity, and motion control.

Watch it cut ↗ Project facts

DIY CNC milling machine for aluminium, designed and built by Ewan Wills

Sht 02 — Project facts

What was the goal?

ProductA CNC milling machine capable of machining aluminium, designed and built from scratch.

FocusMechanical accuracy, structural rigidity, and motion control — the three factors that decide whether a home-built mill can cut metal rather than just plastic and wood.

DisciplinesMechanical design · Motion systems · Controls

EvidenceWorking demonstration video: CNC mill cutting video (YouTube)

DesignerEwan Wills — solo design and build

Sht 03 — Why it matters

What does it demonstrate?

Structural design under load

Aluminium cutting loads expose any flex in a machine frame. The mill's structure was designed for rigidity first, so cutting forces don't turn into chatter and dimensional error.

ii.

Motion control

Accurate multi-axis motion — the same discipline behind the gantries, rigs, and automation systems the studio designs for clients.

iii.

First-principles capability

Designing a machine tool from scratch — not assembling a kit — is the clearest proof of end-to-end mechanical design capability: from concept and CAD to a machine that cuts metal.

Sht 04 — Frequently asked questions

Quick answers.

What is this CNC milling machine?: A CNC milling machine designed and built from scratch by Ewan Wills, a UK-based product designer with a robotics engineering background. It is intended for aluminium machining, and the design work focused on mechanical accuracy, structural rigidity, and motion control.
Can a DIY CNC mill really cut aluminium?: Yes — provided the machine is designed for it. Cutting aluminium demands structural rigidity (to resist deflection under cutting load) and precise motion control. Those two requirements drove this machine's frame and drivetrain design. A demonstration video of the machine is linked from this page.
Who builds custom CNC and motion-control machines in the UK?: Ewan Wills is a UK-based freelance product designer who designs custom motion systems, gantries, and machine tools as part of an end-to-end product development service — from concept and prototype through design for manufacture to supplier handoff.

Sht 05 — Related

More motion & robotics work.

This mill is one of several motion-control and robotics projects by Ewan Wills, a UK product design studio. Related case studies: automated bolt pick-and-place gantry, MiniCapper lab-automation device, and the in-ear vital sign monitor.