I'm looking for suggestions on how to form or machine shim stock for very small parts such as the click spring (dark blue part) shown in the attached jpg on a hobbyist budget. The thickness of the spring will be approximately 0.032" with the complex form shown. The tip will be bent 90 degrees where it contacts the click (shown in gray). The picture doesn't properly represent the end of the click and the 90 degree bend. The sizes are all to scale with the largest gear being 3.1" to give an idea of the spring size.
Is it possible to mill such material with solid carbide end mills that are coated in TiAIN and how would you hold the part while machining?
Or is it possible to cut this material such as with tin snips to get the rough shape and then file?
Also, when bending the tip 90 degrees would I need to heat it up red hot before bending to keep it from breaking?
Any feedback would be greatly appreciated.
Best Regards.
Carl