•All parts are designed as flat patterns
•We try to machine only one side – opposite side machining doubles labor required per piece.
–Tongues & grooves may be added with a saw or table router.
–Template; break out part, drop into template for opposite side machining
•+/- .2 mm tolerance for template
•+/- .4 mm tolerance from reverse side features to front side features
•Single cutter concept - Quick and easy
–2 mm, single flute, carbide cutters used 95% of the time
–Also 3 mm & 6 mm cutters
–CNC routers very fast – optimized for speed, compromised for rigidity and accuracy
–Don’t pretend to be a machining center!
–1 person runs up to 10 machines; no tool changes, no cutter resets
–Average product comprised of 8 pieces and 2 thicknesses
–Sheet change plus set up for new part in 30 seconds
–Sheet change plus set up for new project in 45 seconds
•Tongue: 1.8 mm wide x 1 mm deep Groove: 2 mm wide x 1.2 mm deep
–Don’t model/CAD/design in if to be solvent bonded by Tool-Less
•Tolerance: +/- .2 mm (.008”)
•Csk added as post operation or machined in by CNC mill.
•Parts not broken out till after machining process is complete – no handling of individual parts until absolutely necessary.
•Flashing designed to provide rigid holding points during machining and is easily broken out after.