The Challenge
The Sensor Watch project—an open-source, Casio F91W-compatible PCB—deserved better than plastic. I set out to build a case that matched the quality of the electronics while keeping the minimalist spirit of the F91W.
Damascus steel was the right choice: visual interest without excess, traditional forging meets CNC precision. The work was bringing together two different worlds of manufacturing to create something that performs as well as it presents.
Design & Process
Design started with the PCB and built outward. Every dimension—lug width, case thickness, bezel profile—balanced what looked right with what's actually machinable from layered steel. Pattern orientation was critical: I positioned the damascus layers to flow with the case geometry.
Machining damascus takes different toolpaths than homogeneous steel—each layer has its own hardness and responds differently to cutting forces. I developed the CAM strategy to account for that. Now I'm refining the finishing process, dialing in the etching to reveal the pattern while keeping the machined surfaces sharp.
Technical Specifications
- Material: Stainless steel damascus with organic flowing pattern
- Compatibility: Designed for Sensor Watch open-source PCB
- Manufacturing: CNC machined from solid billet
- Finish: Polished surfaces with acid-etched pattern reveal (in refinement)
Progress & Next Steps
The case design is locked and working. Machined surfaces mate perfectly with the Sensor Watch PCB. The damascus pattern delivers exactly what I was after—visual depth that enhances the design rather than overwhelming it.
Final step is nailing the finishing process. The right etch brings out the pattern without softening the machined edges. This project took an exotic material from billet to functional prototype, proving you can maintain precision manufacturing tolerances even when working with traditional forged materials.