Full Version: Very fun challenge
From: logojohn [#17]
30 Mar 2007
To: ALL
They wanted a 24"x36" acrylic piece but with recessed areas
for a 12x20 metal headplate and individual 1.5x5 plates.
It was 3/4 inch thick so we had it cut to size and polished.
The recessed areas didn't even have to be that deep since it was only for .020 metal so I figured it couldn't take "that long".
The laser seemed like the logical choice since it would fit without repositioning. But each pass took close to an hour and I lost count on how many passes it took to get barely deep enough . . . basically all day.
The next time they wanted one I used the rotary. I set up the inner area of all the boxes with wide hatch using a .250 parallel cutter with a 1/4" spindle. ( I used the big foot and since the hatch ran in one direction I could use the nose cone without cutter fall-in since I only needed 1 pass) I then made several concentric rectangles close together closer to the edges and used a .020 profile cutter so the edges would be very close to square.
Since plates would cover the acrylic, the lines the cutters leaves wasn't a problem. It only took one pass and maybe a couple hours total. Since the table is only 16x25 I had to reposition it 3 times. I just checked the spacing by taping a piece of thin acrylic over it and adjusting first.
I have on occasion made recessed areas in wood bases for vases and statues etc. If I have to go 1/4 inch deep I use the manual set with several passes. The nosecone is only there to vacuum some chips but doesn't make contact with the surface.
On a related note the rotary is sometimes just faster. I use it for almost all plastic profile cutting. We use a lot of the rowmark vintage gold outdoor for outdoor signs as a lower cost option to cast metal signs.
Because of the thick cap it usually takes at least 3 repeats to get through it. Many times people want a border around the edge. The other day I did a 10x18 and with the border 3 passes took forever not to mention the cutting. A few days later the dreaded reorder for 5 more came in. I rotary engraved the border and cutout with the profile cutter.
I still lasered the few lines of text but it was much faster since it didn't have to cover almost the whole area. The laser results in a deeper black letter and no stroke lines from the cutter.
From: Cody (BOBTNAILER) [#18]
30 Mar 2007
To: ALL
As promised, I remembered my camera Friday....took several pics, but none of them really turned out well. I think my flash was too bright, and I should have turned it off.
Anyway, this is the best of the pictures.
The picture makes the edges of the engraving look cruddy. They are anything BUT cruddy.....they're very sharp and clean. I filled them with gold enamel three times to make sure the end result was as near to perfection as I could get it (no bubbles, very uniform fill level).
My customer picked up her plaque Friday, and just loved it. I told her that I liked it so much that I made a second one to put on display....and that I would wait until after they presented it before I put it up.
I ended up keeping the plaque that I routed with the rotary engraver, and gave my customer the lasered plaque.
Also noteworthy, I ended up using 1" wide trophy tape and clear silicone to hold the marble in the plaque. The tape probably has little effect, but it made me feel a little more comfortable about handling it before the silicone set. I let the silicone set for almost 24 hours before letting my customer take the plaque....just to make sure. ;-)
The plaque will be presented to the widow of the man in the photo. She'll love it.
From: Goodvol (JIMGOOD) [#19]
30 Mar 2007
To: Cody (BOBTNAILER) [#18] 31 Mar 2007
Cody,
That's awesome! It sent a chill through my body when I read the "Safe at Home" inscription. I'm sure his wife will cherish it. Beautiful work! Pat yourself on the back for this one.
Jim
From: Stunt Engraver (DGL) [#20]
31 Mar 2007
To: Cody (BOBTNAILER) [#18] 31 Mar 2007
Pictures rarely do justice, but that one definitely gets your points across.