Making my way very steadily through these Delrin pieces!
It's been a fun and interesting challenge to make these in one complete setup, but it's a success!
The parts aren't complicated and only have a few features on each face; however, doing this on the 3-axis would be tedious and time-consuming. Plus, I would run the risk of scrapping each time I took it out of the machine due to my own errors. So, my boss made a simple podium blank for the 5-axis, which I got to use in manufacturing these parts!
The basic rundown of the sequence is using double-stick tape to attach the raw stock onto the top of the podium, then milling it down to its final outer depth with a shell mill, then using smaller endmills; I could pocket out all the little features.
One of the areas that were a bit of a challenge was getting square corners on the side features of the parts, which required them to past the top height of the fixture plate. I was able to overcome this by cutting into the podium just enough for an endmill to pass by below it; in this manner, I got all the features in a single setup and just had to load new stock on, press the button and come back a few minutes later to rinse and repeat!
I'm getting a lot more confident on the 5-axis overall, and my speed is rapidly increasing from programming to the finished part! :)