Hi Trent,
The few who know me, know the slow progress of my project. I "steal" time
to work on it as work and family take the lion's share of what time I have
available. So you might imagine how both overwhelmed and yet thankful for all
the good ideas that have come from my querie. I hope that more than myself
are benefitting from all the expert attention to the problem. I'm not sure
how long, however, it will take for me to explore all the excellent ideas that
have been proposed. And yet another from you.
Knowing what processes and or machines are available has limited my
thinking on this problem. It never occurred to me to consider EDM to cut the
letters out of something thick enough that nothing further (other than
filleting the draft angle) would be required. I dismissed the idea, as well
as laser cutting of plastic, etc, as too costly a method to consider.
Especially with an uncertain outcome. Repeated experiments could be
expensive. However, drawing on your and other's experience may make it more
likely to be successful in fewer tries. So I'll have to consider your first
idea a possibility. Your second idea, however, I don't quite grasp.
You said an electrode would be machined to represent what you wanted burned
into the part. Would this electrode be the lettering? My lack of familiarity
with the process shows here. Could you clarify? Thanks again for your time.
royce
Trent Dowler wrote:
> I've been watching this thread with a lot of interest. Now my "two cents
> worth".
> If the laser cutting idea doesn't play out as planned, you might try a
> wire EDM machine to "burn" the letters out of shim stock material. The
> only restriction with the EDM is that the material being cut must be able
> to conduct electricity so that rules out all plastic. The wire only
> removes a path that is .010" wide so the corners would be nice and sharp
> if needed. Draft angles being cut on the letters would be very expensive,
> but certainly not outside of the machines ability. Once the letters are
> applied and painted over, the paint would tend to give the letters the
> appearance of having a draft angle due to the shallow thickness of the
> letters and the paints tendency to create a flow across the edge of the
> letters and the mating part. Hard to explain but maybe you'll understand
> what I'm talking about.
> Personally, if I were doing the same project, I would use a sinker type
> EDM. An electrode that is exact like the item to be "burned" would be
> machined and would be used to burn the letters directly onto the part, not
> simply applied to the surface of the part. If this were done the letters
> would need to have material for the EDM to remove to leave the letters.
> Or, the letters could use the existing flat part with the letters in
> somewhat of a pocket (if the prototype used this of course).
> Someone else mentioned you sending them the artwork or drawing and they
> would take a crack at it. I make the same offer. Just let me know if you
> want me to give it a try.
> If the metal stamp idea mentioned in another post were used, you would
> automatically have the draft angle built into the mold due to the draft
> angle used on the stamp.
>
> Later,
> Trent
>
