This is just a quick update on the pattern I started this morning after the activities yesterday. I made several adjustments to the parameters of the gcode path, including reducing the layer height and the stepover to reduce the drag on the router which I’ve decided is underpowered (300W). Those adjustments increased the machining time from about 4 hours up to 9 hours. So, this finished about 6pm which means the estimated was about right from my start time of about 9am. I’m happy with the finish quality but I’m not going to use this pattern except to explain the process due to the first mistake in the pattern of the knife on the right. About midway in the handle you can see where the wood was scarred by an operator error (I was trying to show how the machine could return to the G54 zero and the tool ended up dragging through the surface). If this hadn’t occurred then I would have used the saw to trim the ends and then build the box for the pattern.
So, next step is to cut this pattern again. I’m debating additional modifications to the gcode to speed up the roughing cut and using an angled cutter to add some natural draft to the edges. I’m pleased with the mold lock and the overall quality of the cut so far, keeping my fingers crossed about the quality of mold that we get from this.
Suggestions from speeding up so far include: cutting a border first to the depth slowly and then speeding up the internal roughing cuts, choosing a bigger router, better end mill.
Dr Monroe Thoughts 