• 2 Posts
  • 73 Comments
Joined 2 years ago
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Cake day: July 2nd, 2023

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  • Small squares as pixels would be time consuming, but would allow high detail even without a CNC.

    Drag knife on a cricut wouldn’t be strong enough for thick tile.Mill with a O-flute single flute plastic routing bit would be the way to go. 1/8" diameter, carbide, as fast the spindle will turn. Flute length as short as the tile thickness will allow. You’d want a few spares, you’ll probably break a couple getting it tweaked. Start at .030 chip load, full width and depth, probably don’t need a finish pass as the edge roughness will increase adhesion and won’t be visible. Don’t use coolant, don’t breathe the dust, wear a P99 or P100 respirator, shop vac with HEPA for cleanup. Some tile may have abrasive fiber in it and will shorten tool life.

    For fixturing, I think I’d use strap clamps and bars around edges. Use tabs between pieces almost like a stencil, lot of CAM software has a setting for auto tabs on profile cuts, cut from center to edges. Vacuum tables can be real temperamental, slow way down and still tab if trying to hold with vacuum. Double sided carpet tape can do it but has to be removed with acetone and IDK if that would effect the tile.

    Just spitballing, I’d be afraid metal mesh might cause de-adherence over time, especially if it corordes. I really like the mesh idea. Loose cotton fabric like cheese cloth or maybe a little tougher would absorb the tar and might make it even stronger, just have to pour at a high enough temp. Fiberglass sheet might also work.






  • This is a very sharp article. Think I first saw it on Hackaday. I should be using the checklist more often. If there is to be a 3D print bible like Machinery’s Handbook, this article is foundational.

    In particular, chamfers and fillets and their relationship to strength by reducing stress risers is often missed on amateur designs.

    I need to look at crush ribs and ribs for screws/bolts more.

    The idea of a sphere being the most efficent shape is counterintuitive when most mechanical design is inherited from subtractive manufacturing. Also, speed holes reducing strength and increasing material usage is wild. These are powerful ideas that are going to cause almost a philosophical change in manufacturing. It’s going to take decades. Absolutely mind-blowing stuff when you really think about it.

    DFM, in general, is a woefully underappreciated aspect of engineering. One of the great things about 3D printing is that the designer is generally forced to eat their own dog food.

    MEs should recieve more education about DFM. 3D printing would be an easy way to force them to understand the difficulty poor design causes. Of course, DFM for subtractive is a larger and more complex subject, but printing would at least teach the lesson with a little sting.