Can a CNC machine make all the cuts and mills and grinds to complete carbon fiber scales?

[BloodyDonnie]

I dont have any experience with this so apologies if it's a dumb question. I have designed knife scales on Fusion 360. I wanted to know if just with the file, a cnc machine can make it.

The scale design is contoured, not flat

 

[HSC ///]

you need to have the right post processor for the specific CNC machine

A Post processor converts your fusion file into usable machine code

sometimes the cad cam company will provide you a post processor

so you need to know what machine you are going to cut the part on, Fadal . Haas etc

Then the machine shop needs to prove your program so they don’t crash their machine

 

[Ocelot85]

I'm a CNC programmer and machinist by trade, a programmer would use your model in a CAD/CAM suite such as MasterCAM, SurfCAM, GibbsCAM, etc to apply digital tool paths to the geometry and then as Harbeer said post the tool paths through the post processor that is appropriate for your milling machine. The post processor converts the digital information to code the machine reads, the most popular being G&M code that is read by many machines which includes Fanuc, Haas, Tosnuc, etc controllers.

Since you admittedly don't have any experience programming or machining, you'd need to send the file to a shop to machine the scales. Though for a one off set of scales it could be rather expensive considering the pay rate of competent programmers and machinist (ask Nathan the Machinist about that), set-up cost and tooling. As long as the design is reasonable and you have the money I see no reason why it couldn't be done though, 3 axis contour milling isn't an uncommon process. I read that Aldo the new jersey steel baron is going to be offering scale machining services eventually, maybe reach out to them they might be able to help you with your project.

 

[BloodyDonnie]

I'm a CNC programmer and machinist by trade, a programmer would use your model in a CAD/CAM suite such as MasterCAM, SurfCAM, GibbsCAM, etc to apply digital tool paths to the geometry and then as Harbeer said post the tool paths through the post processor that is appropriate for your milling machine. The post processor converts the digital information to code the machine reads, the most popular being G&M code that is read by many machines which includes Fanuc, Haas, Tosnuc, etc controllers.

Since you admittedly don't have any experience programming or machining, you'd need to send the file to a shop to machine the scales. Though for a one off set of scales it could be rather expensive considering the pay rate of competent programmers and machinist (ask Nathan the Machinist about that), set-up cost and tooling. As long as the design is reasonable and you have the money I see no reason why it couldn't be done though, 3 axis contour milling isn't an uncommon process. I read that Aldo the new jersey steel baron is going to be offering scale machining services eventually, maybe reach out to them they might be able to help you with your project.

Oh I see, yea I am planning to find a shop that can do it, do you know around how much it would cost for the whole process if it's just a one off? Like a rough idea?

Thanks for such in depth info!

 

[BloodyDonnie]

Yea I'm not sure about the program conversion process, I'm planning to take it to a shop and have them do it. Just wanted to know if the CNC machine is able to do completely sculpt the scale from start to finish, aside from some smoothing out and sanding in the end

you need to have the right post processor for the specific CNC machine

A Post processor converts your fusion file into usable machine code

sometimes the cad cam company will provide you a post processor

so you need to know what machine you are going to cut the part on, Fadal . Haas etc

Then the machine shop needs to prove your program so they don’t crash their machine

 

[HSC ///]

Yea I'm not sure about the program conversion process, I'm planning to take it to a shop and have them do it. Just wanted to know if the CNC machine is able to do completely sculpt the scale from start to finish, aside from some smoothing out and sanding in the end

nobody’s going to do a one off for you but if you want to pay for it it’s probably $1000 or more

Machine can sculpt the scales but it will take more time and you will pay more and you’ll still have minor what are known as scallops to sand.

To be quite frank and honest with you... nobody’s going to want to take that job or even quote it

Machine shops need long running repeat business and they’re willing to invest in the set up and the tooling for many many parts

 

[BloodyDonnie]

nobody’s going to do a one off for you but if you want to pay for it it’s probably $1000 or more

Machine can sculpt the scales but it will take more time and you will pay more and you’ll still have minor what are known as scallops to sand.

To be quite frank and honest with you... nobody’s going to want to take that job or even quote it

Machine shops need long running repeat business and they’re willing to invest in the set up and the tooling for many many parts

Oh damn yea that is far more than I was willing to pay, I guess I will try my hand at cutting it and grinding it all by hand tools haha.

 

[Drew Riley]

I dont have any experience with this so apologies if it's a dumb question. I have designed knife scales on Fusion 360. I wanted to know if just with the file, a cnc machine can make it.

The scale design is contoured, not flat

Can you post a screen shot of your design? Whether or not a "CNC Machine" can make it will depend on several factors. At the very least, it may require multiple setups.
Fusion can be used to run a simulation that will show the tool path and a pretty accurate representation of what your part will look like before, during and after each op, but it's not exactly something you can just stumble through if you've never done it before. A picture of the scales should be enough to give you an idea of what it might take though.

 

[Ocelot85]

Oh I see, yea I am planning to find a shop that can do it, do you know around how much it would cost for the whole process if it's just a one off? Like a rough idea?

Thanks for such in depth info!

To even give you a rough idea i'd have to see the file and figure out set-ups, fixturing requirements and tooling, it shouldn't surprise you though for a programmer who is freelancing to charge 30-50+ dollars an hour for 3 axis contour milling work depending on their experience level. That excludes all of the other associated machining costs. This is not an offer to do the work. Simply giving you an idea.

For one set of scales for a custom knife, you'd be better off finding a knife maker here who can grind out a set for you.

 

[REK Knives]

Doesn't fusion 360 have a native cam application in it? Does that still have to go through the post processor?

If a knife maker were to get set up to machine their own scales wouldn't a cnc router work fine? I wonder if there are any compatible with fusions cam

 

[Ocelot85]

Doesn't fusion 360 have a native cam application in it? Does that still have to go through the post processor?

If a knife maker were to get set up to machine their own scales wouldn't a cnc router work fine? I wonder if there are any compatible with fusions cam

I know a local programmer, machinist, knifemaker who is a friend who uses Fusion 360. He loves it, I haven't used it yet. Yes though, there are post in Fusion but it doesn't help if you can't read the code output from the post processor. Trust me, post processors can insert strange moves and crashes and if you don't know what you're looking for you're flying blind. You need to be able to edit code manually at the machine for those rare instances. I would rather have a mill than a router personally, more precision, versatility, and rigidity also for other work.

 

[Drew Riley]

Doesn't fusion 360 have a native cam application in it? Does that still have to go through the post processor?

If a knife maker were to get set up to machine their own scales wouldn't a cnc router work fine? I wonder if there are any compatible with fusions cam

I just built a 4x4 router and am using it with fusion 360 and Mach3. I cut micarta and G10 on it with little issue. It’s no where near a mill, but it gets the job done for the most part.

 

[REK Knives]

I just built a 4x4 router and am using it with fusion 360 and Mach3. I cut micarta and G10 on it with little issue. It’s no where near a mill, but it gets the job done for the most part.

Yeah just having one dedicated to make handles would be amazing. Would love to see some pics, maybe a separate thread or pm?

 

[Kevin Wilkins]

I dont have any experience with this so apologies if it's a dumb question. I have designed knife scales on Fusion 360. I wanted to know if just with the file, a cnc machine can make it.

The scale design is contoured, not flat

Yes!

 

[Drew Riley]

Yeah just having one dedicated to make handles would be amazing. Would love to see some pics, maybe a separate thread or pm?

I’ll see about taking a few pics when I get home, and maybe start another thread. I have a few pics of stuff I’ve been cutting on my Instagram, though no great pics of the machine really.

 

[Nathan the Machinist]

There are some things that I can clarify here.

The post processor is not generating your tool paths. a competent programmer has to develop the tool paths and machining strategy to make the cuts. Once those motions are created they're run through a post processor to Taylor the specific output to a specific machine tool.

most CNC routers, toy routers I mean, are not going to do a very good job in carbon fiber, you're probably looking for a machining center to run this on.

you can have a finished machined set of scales ready to go with no additional work, there should be no sanding needed. The step-over can be fine enough that it is not visible or the tool motions can intentionally leave behind machined artifacts that are a part of the design.

When running production, scales cost about $2,000 for the first set and $20 for each additional set. Some shops will subsidize that first set if the numbers are adequate.

I imagine that a prototype set of scales can be done for a few hundred bucks. there are places online who will offer prototype Machining from your cadfile. These may need a little bit of sanding.