I had hope for a cheap method to machine the matched die molds we need to process the braided triangular carbon fiber tubing for our Series 1 Chair prototype legs and support frame. All went well for the first hour, as we were taking every precaution by running super slow. Since the X-Carve has no means to deliver coolant, we were using WD-40, as recommended by folks using manual mills.
Well the end mill eventually “gummed-up” and lost its ability to cut. Given the biggest problem with the X-Carve is lack of rigidity in the X-axis, the force of metal hitting metal without removing it jarred the router about 0.2” off its tool path, ruining a really nice piece of MIC-6.
A real mill has the ability to deliver a constant flow of coolant to keep the cutter cool throughout the entire milling process.
We scrapped the project, and will use the X-Carve for its intended purpose: cutting our wood veneer inlays and machining much softer polyurethane tooling board.
We will either machine male masters using the tooling board and layup carbon fiber molds for the matched die tooling, or outsource the work to our partner at Xometry.
Nothing comes easy in the world of new product development. All we can do is get up and move on to Plan B (or C or D)!
