I’m a qualified tool maker by trade. My skills were developed in a tightly packed tool room of a factory running hundreds of mold and press tools. This was the perfect pressure-cooker environment to develop my diamond-sharp skills.
Hi, I’m Stuart Faulkner
I’m a qualified toolmaker by trade. My skills were developed in a tightly packed tool room of a factory running hundreds of mold and press tools. This was the perfect pressure-cooker environment to develop my diamond-sharp skills.
My Services
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3D Design
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Part Simulation
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CAM Programming
My Skills
Utilising CAD and CAM software to design and fabricate.
Avid Learner
There is nothing more exciting and stimulating than learning something new, for this reason I will always be a student to life. I am not content with slowing down or leveling out, there is always room for growth.
Delicate Precision
My tool-making background has taught me the patience and attentiveness necessary to achieve the tight tolerances required for making perfectly functioning production tools.
Problem Solving
In a factory that runs all day and night there seems to be a never ending stream of problems to surmount, learning to dynamically solve and not just patch them is key to maintaining an upward trajectory.
Mold Tool
Freezer Draw
A mold weighing over 3 tonnes, built using a new cnc machine and new CAD software, both of which I was unfamiliar with, steep learning curve to say the least.
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Mold Tool
Packaging Spacer
A component created for the sole purpose of making another component stackable for shipping and to avoid damage to the component.
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Mold Tool
Strain Relief
This was my very first mold tool entrusted to me to make, a funny aside is that I had to retroactively design the model for the tool since the original was all scribbles on paper which I was far more comfortable with than CAD, at the time.
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Mold Tool
Support Plug
A small tool.
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Mold Tool
Cable Clamp
My favourite mold tool I had the chance to design and fabricate in isolation. There were some machining challenges to overcome, one method to incorporate the fine details was to make a copper version of the component (copper is much softer than tool steel) and burn away the steel using an electric discharge machine.
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Press Tool
Electrical Contact Arm
A large copper component used to switch between power sources in a large industrial electrical switch boxes used in substations.
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Press Tool
Copper Dropper
Another large copper Component very similar application to the above.
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Press Tool
Sink Clamp
A stainless steel component used to secure a sink to counter top.
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Press Tool
Diving Buckle Component
Just one part of a larger assembly for a diving outfit.
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Press Tools
Door Latching Component
A final forming tool for a door latching mechanism used in the same electrical switch boxes as the copper components above.
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Mold Tools
Cable Clamp
Mold tools are a form of mass production tools wherby a negative imprint of the desired object/shape is created in an enclosure and the enclosure is filled with material (usually plastic).
Press Tools
Under-mount Sink Clamp
Press tooling is a method of shaping thin metal parts whereby a strip of material is fed through the upper and lower halves of the tool being actuated by a press machine. The various stages of the tool progressively cut and bend the part into shape.
Creative Projects
Mandala Flower
While technical projects are the bread and butter, what really keeps me going and my mind alive is my aimless creative pursuits.
Creative Projects
Spinner
My very first “private” job after I learned to use CAD and a cnc, fidget spinners were all the rage back in the day…
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Creative Projects
Chillum
A traditional smoking pipe I became interested in making after seeing it contained an awesome geometric taper which acts as the filter.
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Creative Projects
Draw Knife
A backwards drawing knife used for carving and debarking trees, all parts except the nuts and bolts were up-cycled.
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Creative Projects
Mandala
This is a sacred geometry inspired ornamental token with zero practical purpose but was a great source of fun to make.
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Conclusion
All about creation
I have one basic passion, a passion to create using my expanding knowledge base and range of skills.
What People Say…
Brett Pentz
Working with Stuart reminded me of my inquisitive younger self. Always keen to learn new things and eager to understand tasks and objectives intricately.
Tool Maker at ….
Jeron Van Strydom
Whilst overseeing Stuart through his apprenticeship I noticed how he always gave each task 100%. Stuart takes pride in doing a job properly. He shows great potential for design work and is a talented problem solver.
Tool Maker, Jasco Electrical Manufacturers
Pascal Mkhize
I enjoyed working side by side with Stuart at Jasco. He was a great team member for bouncing issues or ideas off. Stuart’s mind is wired differently to most & his fresh perspectives were always welcomed in the toolroom.
Partner, PMB Turbocharger Repairs