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'[EE] Waterjet cutting'
2012\02\21@162932 by IVP

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Hi all,

a current project calls for a simple low-speed gearbox using involute
gears, made of 3 - 4mm acrylic or polycarbonate. It's not meant to
function at the full speed of the eventual device, but as a slow-motion
display / representation. It *has* to be waterclear material

The largest is 80mm diameter, with 80 teeth, the smallest is 20mm with
20 teeth, so the width of each tooth is pi mm. The teeth don't have to be
rxact involute, as long as they mesh reliably

The reply just now to asking for a quote (http://www.laserstream.co.nz/)

"Unfortunately we are unable to help in this instance as we would be
unable to get the detail required"

That seems whack to me, considering the resolution mentioned here

http://en.wikipedia.org/wiki/Water_jet_cutter

Anyone here had something similar or better cut ? Or am I expecting
too much ?

TIA

Jo

2012\02\21@164550 by Richard Prosser

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Joe,

Have you tried other suppliers - eg <http://www.fabrum.co.nz> They appear to
have acrylic capability - look at their "products for sale". They clam
to do gaskets on a 24hr turnaround.

RP

On 22 February 2012 10:29, IVP <spam_OUTjoecolquittTakeThisOuTspamclear.net.nz> wrote:
{Quote hidden}

>

2012\02\21@164643 by Bob Blick

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part 1 1095 bytes content-type:text/plain; charset="us-ascii" (decoded quoted-printable)

I use waterjet gears all the time on prototypes, see attached. The
smaller gear has roughly the same pitch as what you describe and is
aluminum.

Cheers,

Bob



On Wed, Feb 22, 2012, at 10:29 AM, IVP wrote:
{Quote hidden}

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part 2 27766 bytes content-type:image/jpeg; name="waterjet_gears.jpg" (decode)


part 3 181 bytes content-type:text/plain; name="ATT00001.txt"
(decoded base64)

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2012\02\21@165649 by Mike Harrison

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On Wed, 22 Feb 2012 10:45:27 +1300, you wrote:

>Joe,
>
>Have you tried other suppliers - eg <http://www.fabrum.co.nz> They appear to
>have acrylic capability - look at their "products for sale". They clam
>to do gaskets on a 24hr turnaround.
>
>RP
>
>On 22 February 2012 10:29, IVP <.....joecolquittKILLspamspam@spam@clear.net.nz> wrote:
>> Hi all,
>>
>> a current project calls for a simple low-speed gearbox using involute
>> gears, made of 3 - 4mm acrylic or polycarbonate. It's not meant to
>> function at the full speed of the eventual device, but as a slow-motion
>> display / representation. It *has* to be waterclear material

Why waterjet as opposed to laser cutting?

2012\02\21@170507 by IVP

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> Have you tried other suppliers - eg <http://www.fabrum.co.nz>

Thanks, I'll drop them a line. I'd not tried others as Laserstream are
local for me and probably the best-known and longest-established up
here

Even though I'm not aware of exactly what they *can* do, I have to
wonder if I've been fobbed off by someone on the front desk who
perhaps assumed they couldn't do this. Would like to have seen a
maker's name on the waterjet cutter

If Fabrum say they can do it, I'll ask Laserstream why they can't

Jo

2012\02\21@170508 by IVP

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Thanks Bob. Nothing wrong with those, pretty much what I want done

Jo

2012\02\21@170919 by IVP

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> Why waterjet as opposed to laser cutting?

If laser cutting can do it then that's fine. Laserstream didn't suggest
another method as an alternative. I assumed, from their blurbs, that
waterjet would be more suitable for a heat-sensitive material. Bob's
gears show that it can be done with waterjet

I'll ask

Jo

2012\02\21@171645 by Mike Harrison

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On Wed, 22 Feb 2012 11:09:14 +1300, you wrote:

>
>> Why waterjet as opposed to laser cutting?
>
>If laser cutting can do it then that's fine. Laserstream didn't suggest
>another method as an alternative. I assumed, from their blurbs, that
>waterjet would be more suitable for a heat-sensitive material. Bob's
>gears show that it can be done with waterjet
>
>I'll ask
>
>Joe

Laser is pretty much the default way to cut acrylic, & leaves a clear finish. Probably much more
widely available, therefore cheaper, than WJ.

2012\02\21@171938 by Carl Denk

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Just a brainstorming idea. Recently there was a thread on the mold material for casting epoxy. Would this method be applicable. Castable water clear materials are available. Just order the gears in an inexpensive material and make clear copies.

2012\02\21@173134 by IVP

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> Laser is pretty much the default way to cut acrylic, & leaves a
> clear finish

That I did not know. Thank

2012\02\21@173331 by IVP

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> Laser is pretty much the default way to cut acrylic

Laserstream respond to that -

"We don't water cut acrylic as it is too brittle and the laser would melt
the fine detail

2012\02\21@173919 by IVP

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> Just a brainstorming idea. Recently there was a thread on the
> mold material for casting epoxy. Would this method be applicable.
> Castable water clear materials are available. Just order the gears
> in an inexpensive material and make clear copies

Casting would work, although I'd like to leave that as a last resort
because of the fiddling and labour. I've already got the materials to
do it (silicone and water-clear polyester resin)

One other possibility is clear disks, which I can turn on the lathe,
with toothed edging stuck on (eg a drive belt turned inside out). Not
quite as elegant perhaps but done right the two-tone finish might
look OK. Or if Laserstream could cut a metal ring with teeth and I
bond that to a clear disk. A shiny brass or black powder-coated ring
would actually look quite nice

Jo

2012\02\21@174216 by glen wiley

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Have you looked at http://www.ponoko.com/ - these guys appear to have some
decent capability for this sort of thing.

On Tue, Feb 21, 2012 at 5:39 PM, IVP <joecolquittspamKILLspamclear.net.nz> wrote:

{Quote hidden}

>

2012\02\21@175009 by IVP

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> Have you looked at http://www.ponoko.com/

Thank

2012\02\21@182358 by IVP

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> Have you tried other suppliers - eg <http://www.fabrum.co.nz> They appear
> to have acrylic capability

In the waterjet gallery there's an example

http://fabrum.angel.datapower.co.nz/gallery.html?gid=3

If the first image you see is 'Salt water intake strainer', click 'Previous'
seven times

Joe

2012\02\21@182659 by Chris Roper

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Sounds like a good job for a 3D printer.
Do you know anyone with a MakerBot

2012\02\21@183731 by IVP

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> Sounds like a good job for a 3D printer

A Makerbot is the sort of thing I'd love to have in the workshop

Looking through their materials it's not...um...clear if they have
a truly water-clear filament

This might be the nearest

http://store.makerbot.com/pla-4043d-1kg-spool-3mm.html

says "clear" but also "lusterous". I suspect transluscent

Jo

2012\02\21@184848 by Alex Harford

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On Tue, Feb 21, 2012 at 3:37 PM, IVP <.....joecolquittKILLspamspam.....clear.net.nz> wrote:
>> Sounds like a good job for a 3D printer
>
> A Makerbot is the sort of thing I'd love to have in the workshop
>
> Looking through their materials it's not...um...clear if they have
> a truly water-clear filament

Depends on the extruder I believe. At the Vancouver Maker Faire, one
of the gentlemen running the Makerbot demo gave me a gear that didn't
pass quality control. He said not to worry about my kids chewing on
it, as it's corn starch based. I expect that it would dissolve in
water

2012\02\21@190443 by IVP

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> I expect that it would dissolve in water

Yes, I saw that. With humidity like it is around here and the longevity
I'm looking for I think PLA wouldn't be suitable

'fraid it'll have to be evil ol' non-degradable plastic. Sorry plane

2012\02\22@014637 by IVP

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> How thick?

> And http://www.pololu.com/catalog/product/749
4mm or 6mm, which Pololu say they can do with laser

http://www.pololu.com/docs/0J24/3#cannot_cut

I've challenged Laserstream because this page says they DO cut
acrylic and polycarbonate

http://www.hsmeng.co.nz/profile-cutting/laser/

Laserstream did say that fine details will be lost, understandable, so
I've asked them how fine is "fine". If it's to 0.4mm or better resolution
(Pololu) then that's quite acceptable

Joe

2012\02\22@163543 by William Wilson

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-----Original Message-----
From: EraseMEpiclist-bouncesspam_OUTspamTakeThisOuTmit.edu [piclist-bouncesspamspam_OUTmit.edu] On Behalf Of IVP
Sent: Tuesday, February 21, 2012 5:09 PM
To: Microcontroller discussion list - Public.
Subject: Re: [EE] Waterjet cutting


> Why waterjet as opposed to laser cutting?

If laser cutting can do it then that's fine. Laserstream didn't suggest another method as an alternative. I assumed, from their blurbs, that waterjet would be more suitable for a heat-sensitive material. Bob's gears show that it can be done with waterjet

I'll ask

Joe
--------------------------------


I've made gears and gear boxes of plexiglass like you are referring to using laser cutters and waterjets.
Both work equally well and both required a few teeth to be cleaned up using a file and sandpaper.
Fifteen minutes cleaning a few teeth is much better than hand cutting all of the teeth.

And glycerin makes a nice clear lubricant for the gears once it is assembled.




Cris Wilson
Information Resource Consultant
College of Architecture, Arts, and Humanities
Clemson University
864-656-6081

2012\02\22@164550 by IVP

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> I've made gears and gear boxes of plexiglass like you are
> referring to using laser cutters and waterjets

Thanks. I'm still waiting back for a couple of responses. Why such a
simple line of enquiry has gone pear-shaped I don't kn....well, actually
I do know exactly why. I'd be surprised if this didn't end up with me
getting very ticked off after 4 days and talking to someone's manager

> And glycerin makes a nice clear lubricant for the gears once it is
> assembled

Probably won't use a lubricant as the speed will be low and also
don't want to retain dust and fluff. Perhaps a little on the teeth faces
if (I ever get these made and) they haven't got a smooth finish

Jo

2012\02\23@122331 by Adam Field

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> Thanks. I'm still waiting back for a couple of responses. Why such a
> simple line of enquiry has gone pear-shaped I don't kn....well, actually
> I do know exactly why. I'd be surprised if this didn't end up with me
> getting very ticked off after 4 days and talking to someone's manager
>

I'll second the ponoko.com link that had been posted earlier:

http://www.ponoko.com/make-your-own/toys/gears-1359

I've used them to make front panel parts, their service works pretty well

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