[lagfish]

Hi,
I am trying to make a 2D shape out of a 0.0005" thick stainless sheet, and was wondering if anyone has any suggestions? The part is very small, 5mm in diameter, the maximum cutting diameter is 0.005", and precision is +-0.001".

My initial idea was laser cutting, but we don't have a laser cutter that can do metal so I will have to get it sent out. I was also thinking of superglueing the sheet onto a thick plate, and using a 0.005" endmill. Anyone have any experience with this kind of stuff? Thanks

[il_performante]

hi,
I've cut 0.004" thick silver foil by sandwiching several layers of the foil, interlaced with paper (to achieve daisy chained parts) between two thin layers of aluminum. and then cut through them.
Or just make a punch and die to cut them out.

hope this helps.

Marco

[fatal-exception]

Punch :stickpoke Only if you are able to make the punch parts. Sometimes the best way to make parts is to wait for a few weeks. By then, you already know the right way to make the part.

Small files might be your best bet.

[lagfish]

Marco,
What size end mill did you use? The problem with using 0.005" endmill is that I can't cut very deep.

[il_performante]

Lagfish,
fortunately i was able to get away with a 1/16" and cut 1/8" deep.
You might need to sandwich your foil between thin plastic sheets. so they are easy to cut through. And i hope you have a lot of spindle RPM.

good luck

Marco