Built by Ferra Designs Inc. for a private law library, the stair, catwalk and structural components were machined from solid 304 stainless, fabricated and finished in shop. I started as one of a five man crew by design engineering, detailing and machining every component. As head machinist I tooled up the CNC machine shop from scratch, including a 30HP, 4-axis Haas VF4 mill and Hardinge toolroom lathe. I ran CAD/CAM, trained operators and oversaw fabrication of the library components as the company grew. Ferra has expanded to over 50 employees with new facilities and an even wider set of capabilities, able to handle several such projects in parallel.
Above: Spiral stair Solidworks model and top view from landing. Catwalk assembly contained 2000+ metal and glass parts. Glass connectors must allow 3 degree movement at attachment points to allow expansion of the metal.
Below: Crane lift of the upper 3 ton stair section. Right: Each of the two sections were completed on a structural fixture, allowing transport and rigging on site. Detail TIG welding treads in place from the back side.