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Hi! I’m Filip Ljevar, a postgraduate student at the University of Maribor (Slovenia) studying Engineering and Management. My background is in CAD surface modeling and manufacturing technologies, and I also work as a design engineer at an R&D company that focuses on sheet metal forming. I’m passionate about pushing engineering design to the next level and sharing what I learn along the way.
A Workshop Challenge Sparks Innovation
In my early days as an engineer, I was always drawn to hands-on problem-solving. Working in a small workshop, I kept running into the same issue: we just couldn’t find a machine vise that ticked all the boxes. A machine vise is a tool that holds stock material firmly in place during CNC machining. It’s especially crucial in 5-axis CNC milling, where the material must be accessible from at least five sides. We needed something simple, lightweight, rigid, and slim enough to give the tool full access around the part—especially for those tough angles. But every vise I found was either bulky, overpriced, or came with proprietary add-ons that locked us into expensive accessories and spare parts.
That frustration became my motivation. I set out to design a machine vise that could handle it all—versatile, accessible, and easy to maintain. After a lot of development and testing, I filed a Slovenian national patent (SI 26467 A) to bring this solution to life, starting my journey to rethink what a machine vise could be. I’m grateful to Prof. Dr. Jožef Predan and Prof. Dr. Marko Kegl for their mentorship throughout this project; their guidance was a game-changer.
A highlight for me was presenting my project at the 15th Industrial Forum IRT 2024, where I earned 2nd place in a student innovation competition by the Faculty of Mechanical Engineering at the University of Ljubljana. That recognition really validated all the hard work.
Open-Access Machine Vise Design Idea
My main goal was to create an open-access vise that workshops wouldn’t feel trapped by. Too many existing vises come with proprietary interfaces that make simple repairs or sourcing replacements a pain without returning to the original vendor, often at high costs. I wanted to change that narrative and design a vise that offered flexibility, high performance, and freedom from those limitations. My solution, optimized for 5-axis CNC milling, integrates a modular, open-access approach that could help other engineers avoid common industry headaches.
I drew inspiration from the work of Brandon Sander at Inheritance Machining, who used split clamps in dovetail guide channels for workshop fixtures. With that in mind, I added my own twist: a parabolic wedge to increase clamping force. This design uses the pulldown effect of split clamps to pull the moving jaws securely toward the body, providing the strength needed without sacrificing access.
Navigating Challenges in Machine Vise Design: Key Features and CAE Insights
Developing this vise wasn’t without its challenges. With limited resources and time, I leaned heavily on computer-aided engineering (CAE) simulations in SOLIDWORKS instead of physical prototypes. Finding industry benchmarks for machine vise performance was tough, so I had to rely on a mix of gut instinct and trial-and-error. Each iteration taught me something new, and those simulations became invaluable in fine-tuning the design to meet real-world demands.
The vise was designed with 5-axis CNC machines like the Haas UMC 750 in mind but is adaptable to other setups. It features 150 mm-wide jaws and an opening range from 80 to 280 mm, holding parts 180 mm above the table. The combination of the parabolic wedge and split clamp design means strong grip and full access from all sides, which is essential for precision work. This balance of strength and accessibility sets my vise apart from traditional models.
Open-Source Hardware for Machine Vises
One of the most exciting parts of this journey is the potential to share this project with the open-source community. Once the prototype is finalized, I plan to register it with the Open Source Hardware Association (OSHWA) to encourage community-driven enhancements. I hope that sharing the documentation and design can set a new standard for how machine vises are built, tested, and maintained, letting engineers around the world collaborate on improvements.
If there’s one piece of advice I’d give to other engineers, it’s this: start prototyping as soon as you can. Looking back, I wish I’d tested even 3D-printed models earlier. Simulations are great, but nothing compares to having a physical prototype in hand to see what works and what doesn’t. Early testing can save you from going too far down a path that may not hold up, letting you refine your ideas and iterate faster.
I’m targeting summer 2026 to wrap up prototype testing and bring this vise into the real world, using it with actual CNC production parts. For me, this isn’t just about a better tool; it’s about redefining standards, making workshop equipment more accessible, and creating solutions that really meet the needs of machinists and engineers.
Have you ever thought about reimagining a standard workshop tool? What features would you prioritize in creating the perfect machine vise? Share your thoughts and ideas in the comments!
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