Step 3: Prototyping

Picture of Prototyping
skull box prototyping 2.jpg
skull box prototyping 3.jpg
skull box prototyping 1.jpg
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skull box protos 3.jpg
skull box protos 1.jpg
To get a feel for my toolpaths, I ran a prototype in pink insulation foam.  Foam is great for testing because it is cheap, readily available, and easily machinable.  I modified the feeds and speeds to go for the maximum that the machine was capable of.  This meant that I had a complete mockup in my hand in only 30 minutes.  When machining foam, it is critical to vacuum during the process. I ran without coolant and held the shop vac next to the cutter for the entire operation time.  

There are two prototypes here.  The first one that I ran was done with a .050" step down, and is the second set of photos.  The second one, which was the same code as the final metal version, was run with a 3/16" step down.  
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