Thread: Is this a crazy idea?

[QUOTE=Duran86;1836124]Ok, so I'm wanting to get this pattern cut into a sheet of bronze for a wall decoration (black areas would be the parts cut out, plus the white border):



I am thinking 2 feet square and about 1/12" inch think sheet of bronze.

As you can see, it's a pretty intricate pattern. I already consulted with a water jet cutting service in my area, and they said the contact points were too small for water cutting and laser or EDM would be a better suited to the project.

I was originally going to say CNC mill or engraver then realized what you wanted done. I don't think EDM will work as I'm pretty sure they have to burn a hole into the sheet for each cut or shape, some look small. Not sure about laser. All you can do is ask.

Ben

I'd say exactly as is it be impossible for any method. The tips where the geometric shapes touch can't be points, they would need to have some thickness to hold together. With some modification it should be possible by laser cutting in thin sheet, I have no experience with cutting that thick.

Also the cost of a piece of bronze that size plus the cutting won't be cheap so you will want to get it right the first time.

A sheet of 1/2" bronze sounds expensive to me. If it's going to hang inside why not laminate a piece of 1/2" mdf with a thin layer of bronze, then get it laser cut.

The laser will have no trouble getting into sharp corners. Will be expensive though, programming say $80 if you supply the dxf file pus $5 a metre cut.

Good luck.

Ken

Forget EDM. There would need to be a start hole for the wire in every cutout and programing to would be very time consuming. laser is defiantly the way to go.

I think the sheet is only around .083" thick.

I work for a laser cutter in Dandenong Vic. I can tell you now that it will not be cheap, if you can supply the dxf file it will still be at least a few hundred dollars. If we have to draw it it will be somewhat more.

As mentioned previously, the shapes will have to be joined otherwise you just end up with a few thousand random shapes in a box. It will also be wise to place a small radius in all of the sharp internal corners to prevent burning caused by heat buildup as the laser slows down to negotiate the corner.

My boss is reluctant to cut brass and copper because they reflect more than other materials and causes damage to the machine. It may be the same story with bronze.

I'll PM you a link and you can give us a call if you are interested.

The problem with the thing you wish to make is the way that the shapes meet. While Ken is right that a laser can do sharp corners, all the sharp corners meeting in one spot will mean that there will be no corners left as they will all cut into each other. Any design like that has to have sufficient material between the shapes for it to be continuous. I would say 2 to 3mm would be strong enough. anything less than about 2 and instead of having one large shape you are likely to have lots of small ones...

Michael

It would not be possible to cut that pattern from one piece of material and have it look as crisp as the drawing, every contact point will be a circle of 2 to 4mm dia.

Think about putting it together like a parquetry floor and you're starting to get somewhere.

Just a lateral thought...3d printing?. You may be able to find somebody with a printer that cinters bronze powder, just scan the pattern in, no programming fee like laser and anyway laser won't get the crisp definition that you are after. I guess you would print the base solid and then build the pattern to the required depth. Other than that I think assembly from solid bar shapes cut to lengths would probably be the cheapest and maybe the most attractive. And please don't forget to post a photo when you get it finished because it is a really interesting project.

What about photo etching like they do for printing plates?
The background would only be a couple of mm deep but could be filled with a contrasting colour.

Etching would be my suggestion too!