need steel custom cutouts.

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hello, i hope i posted this in the right place.  i need some to have some small cutouts made like for example a letter or a shape like a shield. i can do the drawing in illustrator* it needs to fit in a 1.5 inch circle, so real small.here is one shape, not to scalehttp://farm9.staticflickr.com/8310/8...c1d44e56_o.jpg* i want the shape to be 3/16 or 1/4 inch think of mild steel * i need about 2 to 3 shapes done, 4 pieces each. i guess that is plasma cutter work. i am looking for recommendations where and who does this. or would do it. how much do you think it would cost. appreciate any help. thanks.
Reply:How fine of detail are you looking for? I suspect with plasma you'll loose some of the tail detail as the part is very small. Post your .dxf and I'll cut one out and post a photo of the results. Illustrator can save as .dxf. I think it's save as "AutoCAD Interchange File". I have 1/4" plate on the cutter today. Send me a PM if you can't/prefer not post the .dxf and I'll give you my email.
Reply:that small detail probably needs to be waterjet or etched. not laser and certainly not plasma.  just not sure how thick of metal etching can be done. this is who i use: http://photometals.com/or have a machine shop cut it on a CNC machine. http://karaskustoms.com/
Reply:thanks! i tried to send the dxf as an attachment, it said invalid file. i will pm you. Originally Posted by forhireHow fine of detail are you looking for? I suspect with plasma you'll loose some of the tail detail as the part is very small. Post your .dxf and I'll cut one out and post a photo of the results. Illustrator can save as .dxf. I think it's save as "AutoCAD Interchange File". I have 1/4" plate on the cutter today. Send me a PM if you can't/prefer not post the .dxf and I'll give you my email.
Reply:thank you, i will be following your leads as well Originally Posted by Jimmy_popthat small detail probably needs to be waterjet or etched. not laser and certainly not plasma.  just not sure how thick of metal etching can be done. this is who i use: http://photometals.com/or have a machine shop cut it on a CNC machine. http://karaskustoms.com/
Reply:In creating agreeable cad files from illustrator, all shapes you need to use the Transform tools to create a continuous piece of art. You need to work in wire frame mode and use no fill or stroke colors. Even then, I've had limited success with the artwork being vector and editible in cad from illustrator. Not its strong suit.
Reply:I pulled an outline in inkscape and imported that into my cad program no problem from the jpeg. This part is pretty small. I've attached the profile cut paths for two end mills a 1/64 and a 1/16 flat end mill. I've never used less than 1/8" end mills with my cnc mill... so no idea of cut time. Machining the part would not be my first choice. What is your end use?If you re-drew your part with and kept the cutter diameter in mind... you could get exactly what you want. Another options is to use a v-mill (carve style).Like Jimmy mentioned... plasma wouldn't be my first choice. I suspect the plasma would have detail similar to the 1/16 but with some taper. I'll cut one... it's small and will only take a minute.I'd think wire-edm would be the way to do these with the best detail.Have you thought about making these from metal clay? Form the parts (cookie cutter, mold, sculpt, etc) and bake. What remains is just metal. I have a friend that does silver clay and it's amazing.http://www.metalclaysupply.com/Steel-Clay-s/237.htm Attached ImagesLast edited by forhire; 10-02-2012 at 12:29 PM.
Reply:Also...depending on what you need them for, would probably be a pretty basic casting.
Reply:I got your PM with the updated DXF. I cutout the part. Plasma melts off the fine features.  Attached Images
Reply:Originally Posted by forhireI got your PM with the updated DXF. I cutout the part. Plasma melts off the fine features.
Reply:Originally Posted by Jimmy_popthats very cool of you to try cutting that part for him! props!!
Reply:could you add fillets in the corners of the tail to get away from the sharp corners? also maybe widen the base of the tail a little, it might help sometackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:Originally Posted by brucercould you add fillets in the corners of the tail to get away from the sharp corners? also maybe widen the base of the tail a little, it might help some
Reply:thanks sooo much for doing a sample. i figured that details would be tricky. the wings and the tail look great!  if i go this way i would probably go back into illustrator and take off the head and the tail and try to do that on my angle grinder. and have you do the wings and tail.How much would you charge for each piece?  i tried the do the whole thing on a angle grinder. i should post photos of the results for a good laughbut anyway. i am still following up on the links karakustoms said it wouldnt be cost effective for them to do i should be hearing from photometals real soon. i am trying to get quote a couple of other places as well.i am planning on building a casting furnace in the near future for aluminun, copper and brass, but not steel or iron.i had heard of  metal clay, i even have 2 or 3 books on it about the gold and silver. i knew they had developed brass and bronze not too long ago, i didnt know that had developed steel i have contacted them and ask what kind of steel is it. it has to be strong and weldable. the piece has a structural as well as decorative value.i need these shapes asap because they are going to be welded on my trike hub axles.as soon as complete these follow ups, i will let you know if i need to buy them from you. thank you!   Originally Posted by forhireI got your PM with the updated DXF. I cutout the part. Plasma melts off the fine features.
Reply:i have supplies to build a furnace but i need more castablehowever it wont be for steel Originally Posted by kazlxAlso...depending on what you need them for, would probably be a pretty basic casting.
Reply:I think you should post up the .dfx, and let others try with their different tables. plasma's, etc... Biggest issue is the thickness of the part... Might do way better with lower amps/water table...etc.. I have the 151 too, and know how it can do. Kind of like to see what my new machine will do in that area. Since it's way more powerful in the lower amp ranges (torch design/consumable design) speed is much faster and punches through thicker stock at lower amps. The operator can make a difference, although probably not in this case, because forhire really knows his Thermal machine.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Originally Posted by Brand XI think you should post up the .dfx, and let others try with their different tables. plasma's, etc... Biggest issue is the thickness of the part... Might do way better with lower amps/water table...etc.. I have the 151 too, and know how it can do. Kind of like to see what my new machine will do in that area. Since it's way more powerful in the lower amp ranges (torch design/consumable design) speed is much faster and punches through thicker stock at lower amps. The operator can make a difference, although probably not in this case, because forhire really knows his Thermal machine.
Reply:Originally Posted by mimoosethanks sooo much for doing a sample. i figured that details would be tricky. the wings and the tail look great!  if i go this way i would probably go back into illustrator and take off the head and the tail and try to do that on my angle grinder. and have you do the wings and tail.
Reply:Brand x I tried to to attach a .dfx file here but it said i couldnt post it . invalid link.i am trying with a file sharing site called  dropboxhttp://dl.dropbox.com/u/1736679/falcon.dxfthe falcons will be welded to the face of these hubs i am making the plans are from atomic zombieLast edited by mimoose; 10-03-2012 at 03:33 PM.
Reply:forhire zip file worked fine.I wish I had some 20/30 amp tips for my Esab. 30 amps severs .750 pretty clean.(very slow) The Esab has 30/40 but they just came out with some 20/30 amp tips, also the machine dials down to 15 amps. I have a feeling 3/16 might work, but probably could get a little bit of help with a water table setup. (possibility) I don't have that made yet.  Water works great on thin aluminum/SS stock.  Cut stuff you never though possible without warping.  Not sure if I can do better then a Thermal  (Which I also have,) but you never know until you try? I should have some .250 laying around..Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:I threw the part on the cnc mill and cut it out using a 1/8" cutter. I really should have checked the head/beak clearances more carefully. I attached a screen shot of the interference region. It looks like I shaved a bit off the beak. I think with a little massage work milling will be the way to go. I'll send you a PM with more details.The plasma definitely had some dimensional issues.  Attached Images
Reply:Tried forhire's .dxf.  Out of a piece of .250 angle. 40 amps about 45 ipm 50 was close to the same,.probably with a bit of drawing/ new/different consumables, might get a bit better?Better plate might not hurt either. Attached ImagesEsab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Originally Posted by Brand XTried forhire's .dxf.  Out of a piece of .250 angle. 40 amps about 45 ipm 50 was close to the same,.probably with a bit of drawing/ new/different consumables, might get a bit better?Better plate might not hurt either.
Reply:Originally Posted by forhireThat looks good BrandX. Adding the fillets helped a lot. What was your arc voltage set at... and did you edge start?
Reply:a laser would do it!  I've seen some pretty intricate stuff done with them (albiet, it would be costly!), however that cnc cut out looks promising!the last pic is great. I will take 3 of these, please.  Originally Posted by forhireI threw the part on the cnc mill and cut it out using a 1/8" cutter. I really should have checked the head/beak clearances more carefully. I attached a screen shot of the interference region. It looks like I shaved a bit off the beak. I think with a little massage work milling will be the way to go. I'll send you a PM with more details.The plasma definitely had some dimensional issues.
Reply:Hey Brand X... this really was bugging me this morning. So I ripped open my original cut path... and discovered I had cut to the ID.  I ran the fillet cut path at 100 amps at 100 IPM like I cut most 1/4". Looks much closer to your 40 amp results. Now I have a fair side by side comparison. I just spoke with mimoose and it looks like I'm making two more on the cnc mill. I guess I can quit fooling around with getting a good cut on the plasma.  Attached Images
Reply:lasers would probably be good, no doubt. but probably too expensive for my small job. i got a couple of quotes from waterjet places and i couldnt afford it. Originally Posted by mb_weldera laser would do it!  I've seen some pretty intricate stuff done with them (albiet, it would be costly!), however that cnc cut out looks promising!
Reply:One thing about Plasma, you can keep changing things ,and get different results each time. I find the Hypertherm/Esab and Thermal machines  (85/151/1600) cut pretty similar at top output. Just all way different at the lower outputs.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:thanks for your trouble Brand X, but I ordered 3 from forhire.a very decent try, though. by the way, i envy all of your wonderful toys, i mean tools!  Originally Posted by Brand XTried forhire's .dxf.  Out of a piece of .250 angle. 40 amps about 45 ipm 50 was close to the same,.probably with a bit of drawing/ new/different consumables, might get a bit better?Better plate might not hurt either.
Reply:Originally Posted by mimoosethanks for your trouble Brand X, but I ordered 3 from forhire.a very decent try, though. by the way, i envy all of your wonderful toys, i mean tools!
Reply:not for this job, but it would be fun to get some sheets of copper or nickel silver and start punching out own money..lol. Originally Posted by Brand XI am now wondering if a punch press might be the best tool for the job. If you made 1000's though..   Probably not at that thickness?
Reply:forhire:recieved them yesterday! beautiful. i am excited. thanks for throwing in the extra sample. folks, i will post the other shapes soon.
Reply:i would like to get a quote from folks on this piecesee attachment below:here is the dxf file i hope this works. http://dl.dropbox.com/u/1736679/sankofa%20bird200.dxfi need it in 1/8 inch mild steel instead the harder to cut 1/4 steel. i need 30 of them.i admit i am reluctant to post because it will probably cost more than i can afford but i am asking away. thanks. Attached Images