Impossible aluminium design. Really!?

[lookalion]

Hello all,

I have a base for a product I produce all made up in 3D but because of the 45 degree shelf within it my manufacturer says its impossible to produce in Aluminium. I really like the design and don't want to change it. Has anyone got any way I might be able to get round this problem?

I want it to be in anodised aluminium....

See the design here:
http://www.worldfrontier.com/aluminium-base-design.htm

Thanks for any help you might have.

Regards
Mr Lion

[BigDaddyG]

Mr Lion,
Do you have the solid you could post or send? I say, Yes it can be done! What are your limitations or that of your manufacturer that is the stopper?

[atemylunch]

Lion,
Take a look at these guys.
http://www.nambe.com/
Look at their metal products.
Their salt and pepper shakers/candle-holders are turned 6061 aluminum.
Their platters are cast. The main ingredient in aluminum.
They polish all their pieces.

Get another shops opinion.
Your part could be made on a lathe with live tooling.
Or a 4 axis milling machine.
Yor options are wide open.
You manfacturer may not be interested in producing it.

Good luck.

[motordude]

Hello,
is it sheet metal? If so, then I can`t see why it can`t be made, there are no undercuts. If I were to make it I would use a tube, then make a cone Ø40+- up to Ø125+-. Next step would be to press it to its final shape.

Regards
John

[Rekd]

Surface it on a mill. Easy money.

[lookalion]

Hey all,

Thnaks for the replies,

BigDaddyG - I don't know what a solid is?

Atemylunch: WOW!! I love the turned pepper shakers, impressive chrome looking finifh. You mention 6061 aluminum. Is that a special type? Stronger, better, more chrome like? Why use this.

Is it easier to surface it on a mill, start with a tube. I am now confused.

My manufacturer is in India and not the best in the world. What kind of costs would be involved - is this an expensive design, setup etc? I am getting 1000 produced. A fully chromw look would be brilliant to, is chrome harder and more expensive than anodised aluminium?

Chatting about this is helping. I'm learning a lot thanks to you guys.

Cheers
Mr Lion

[sendkeys]

looks like easy work for 4th axis mill

[turmite]

lookalion if I were in your shoes right now, I would post a request in the forum here on the zone for job quotes. You might be surprised how many offers you get. Or on the other hand, how few!

Mike

ps I could do it in wood for you!

[atemylunch]

Lion,
6061 T6 is an aircraft grade aluminum. It's very common in the US, thus less expensive.
It's used in to many things to mention. It is strong, relativly easy to machine and it polishes very well. The finish you see at Nambe's pieces are not plated, they are machined out of solid piece of aluminum then polished.
When you polish the aluminum it seals it. You don't have to worry about corrosion.
Or using anything to coat the piece after you polish it.
As far as strength is concerened. You average homeowner won't even come close to what this material can take.
The only drawback to these polished pieces is they can be marred easly. If not handled with some care.

You have a computer model(cad, solid, etc.) That makes it very easy for someone to machine the design. There is software out there that can process a computer model into what ever machining need to be done.

I do not know about the availability of 6061 in the UK. I have had some people tell me that is not available out side the US. You have to buy and ship the material to which ever country your having it made in. Then most likely you will not get the same material back.

When it comes to machining you will find that is often not much cheaper to have things made overseas. When you consider costs of shipment. Product quality and consistency, your often better off having your products made nearby.
Since you live in the UK, you have some very good people over there who can do what you need. You just have to find them.
Or do what I did. Learn how to machine, buy your own equipment. Produce your own product in your garage. This may sound expensive, in the long run it's the cheapest option. CNC tools are very flexable machines. Showing you you what Nambe does, is just a small part. These tools are capable of things that would blow your mind.
If you go out looking for shops to make your stuff. Ask to see the shop, look at the tools ask a lot of questions. Do the same here, these guys are very creative with very little.

Good luck &
Talk soon,

Max

It's good hard fun.

[lookalion]

Hmmmm.... yes all ecellent food for thought. Our Indian manuacturers have their issues thats for sure. Quality and timing is difficult for them. I might try the job quote zone on this website to see if anyone out there might be able to make this for us. We actually ship out of Australia back to the USA. Its a complete product and this is just the base I'm looking at. Maybe I could get it put together in the states with the base being made there and the rest of the electrics made in India.

Yes I will have to do further research.

Thanks to all those that have given me their time and advice, its much apreciated!!

Mr Lion

[lookalion]

Hello again,

Correct thickness????

Ok my manufacturer has come up with this method of production:
"We shall have to make a " Hot Steel Dye weighing about 300 kgs from the tool room and then use a Pressure Die Casting Machine ,when the molten for is put in the steel dye it shall be clampem to a presuure of 250tonnes."

My question for the design attached. What thickness should the base be? We need it to be strong enough for shipment but it does not have to hold the weight of anything at all, it just sits there. Is 3mm too much... lighter the better for shipping.

Thanks for your answers and any comments you have on his production technique would be appreciated too.

Cheers
Mr Lion

[lancedulak]

But even i can think of multiple ways to do that. He's talking about injection molding. Thats a process mostly used for plastics. And VERY expensive. Usually only used for high production runs. Consider you have to make a mold etc etc etc.

You could cut those easily on a 4axis mill. The walls would be THICK though.
You could have them stamped in 2 pieces and for a run of 1000 it might be cheap but would require welding.
There are PROBABLY sheet metal machines out there that would roll them. In one operation starting with a tube

Anodising is a process done to finished aluminum. Its done to give the part color and a tiny bit more hardness on the surface. Chroming is plating multiple metals over the original metal. Chrome plating 1000 of those would cost a Fortune. Anodising would cost less.

If your machine shop says it cant be done you need a new machine shop. You should request quotes here. Go to machine shops websites and request quotes (if they refuse to do it that way they arent worth yoru time. YOU are offering THEM money). There is a yahoo group of home machinists who will give you quotes . Some of the groupmembers have Complete high tech machine shops in their homes. Literally. Good luck