Jess,
The prototyping of thin metal parts is best achieved using a laser cutter to
cut the blanks. The forming of the blanks, depending on the geometry and
the amount required can be accomplished with a small press brake. NC
punching can achieve the same result, but some special punches would be
required. I have done parts like the ones you described, and we used the
laser cutter and press brake method.
Regards,
Jim Paravantes
****************************************************************************
Trident Systems Group, Inc. 45737 Henley Dr. Canton, MI. 48187
Voice: 313-844-9033
Fax: 313-844-2652
http://trident-systems.com
E-Mail jim@Trident-Systems.com
****************************************************************************
*
-----Original Message-----
From: Ferrill, Jess B <bferrill@amp.com>
To: 'rp-ml@bart.lpt.fi' <rp-ml@bart.lpt.fi>
Date: Thursday, March 19, 1998 9:58 AM
Subject: RP of Thin Sheet Metal Parts
>In the electrical connector business we frequently need to make rapid
>prototypes of small thin metal parts (typically 0.005 to 0.015 inch or
>0.13 to 0.38 mm. thick) to tolerances in the range of +/-.005 inch (0.1
>mm) or better. The parts might have rectangular or round openings,
>interrupted slots, tabs, etc. The narrowest cut slots or holes would be
>about 0.015 to 0.020 inch (0.40 mm) wide. (The finished or profiled flat
>part might be thought of as similar to a single paper doll cutout).
>
>The profiled parts may then be formed by folding into the final shapes.
>For our quick prototypes we currently use wire and plunge EDM or
>photoetching followed by hand forming using prototype forming dies in a
>small press. Materials might be copper alloys or stainless steel. Sheet
>raw material sizes could be several inches per side on up to feet, but
>individual parts are normally less than three or four inches in the
>longest dimension. Typical prototype runs might be several hundred
>individual parts. Capital costs of the equipment are less a concern
>than time required to produce several hundred parts. Our ideal system
>would also be capable of
>producing thousands of parts until a production stamping dieset could be
>finished.
>
>I wonder if anyone has any fresh ideas. The ideal method would be
>controlled from a solid CAD model or similar quickly generated CAD
>layout (Pro/E with sheet metal module available).
>The ability to cut stacked multiple sheets might offer a speed advantage
>
>I am exploring the following methods to cut the profile shapes in flat
>material:
>
>1) Laser cutting: (suitable for thin metals?, clean edges?, shiny
>surfaces a problem?)
>2) CNC punching or nibbling: (small precision parts, need for lots of
>special punches? speed?)
>3) Abrasive water jet: (capable of narrow slots?)
>4) Plasma jet: (clean smooth edges?, capable of narrow slots?)
>
>Any other ideas or comments on the above would be appreciated!
>
>Thank you,
>
>Britt Ferrill
>AMP, Inc.
>(336) 727-5387
>bferrill@amp.com
>
>
>For more information about the rp-ml, see http://ltk.hut.fi/rp-ml/
For more information about the rp-ml, see http://ltk.hut.fi/rp-ml/
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