- 1/2 in single flute bit
- A design
- CAD to CAM software (in this case, VCarve Pro 6.0)
Step 1: Machine and File Prep
So I cut these with an initial PROFILE, and the a FINISH cut.
Once your file is set up and ready for a cut file to be created now you have to set your bit and feeds and speeds for each cutting path.
Step 2: Initial Profile Bit
- 1/2 inch bit
- 14000 rpm
- 2.25 inches/second feed rate
These are what I found yielded a nice chip out and wasn't too rough on the machine or the tooling.
Step 3: Initial Profile Path Setup
What I do to keep the parts stable in the whole sheet and also maximize vacuum until the pieces are totally cut out is I cut the profile but leave a 1/32 on the bottom so it doesn't quite go all the way through.
And for this initial profiling path I also offset the cut 1/32 of an inch larger so the final pass goes in and shaves the final 1/32 off the side and the bottom on a full depth pass.
Step 4: Finish Profile Bit
- 1/2 inch bit
- 18000 rpm
- 1 inch/second feed rate
This profiling will yield a much smoother edge finish because the bit is faster and it is feeding slower so it contacts the material more times. Depending on your tooling you might have to adjust this because it will want to melt the plastic and gunk up your bit and the edge, so be careful.
Step 5: Finish Profile Path Setup
The full depth pass will result in a uniform edge without depth passes making it easier to finish treat the edges.
For this full dept pass don't forget tabs. Remember this is shaving off the 1/32 inch on the side and the bottom, so I just make the tabs 1/32 of an inch and 1/4 inch wide which is more than enough to hold the pieces in.
Step 6: Part Preview
Step 7: Part Removal
I just take a deadblow and a chisel and put the flat part of the chisel against my piece and lightly tap the chisel and it breaks off the tabs smoothly.
So this is how you get thick acrylic pieces cut out with a easily finished edge. Finishing the edge to clear will be in my next instructable.