OMAX Waterjet Cutting Precision Board HDU

Waterjets have been becoming increasingly popular due to their ability to cut any type of material that comes in the shop door, including Precision Board HDU.  You can never predict what the next job is going to require, so having the capability to cut any substrate is a great addition to any shop arsenal.

OMAX Corporation, a manufacturer of premium waterjet cutting machines, recently filmed cutting of Precision Board HDU in order to show just what this amazing technology can do.  Check out the video below and dial the settings info in if you plan on cutting high-density urethane anytime soon.

Waterjet cutting is a high-performance industrial cutting method that offers some unique benefits in comparison with milling, plasma cutting, or hand carving. With advancements in technology, waterjet cutting of Precision Board tools and signs has become a more attractive option.  Because water jet cutting produces no heat-affected zone (HAZ) like other cutting methods, it can safely cut urethanes, metals, and other materials without affecting their structural properties. Waterjet cutters are capable of extreme precision, and can produce intricate designs and complex shapes when used with CAD software and specialized machining heads.  It also eliminates dust in the air from cutting.

omax

In this demonstration, a MAXIEM 1515 is used to cut out the OMAX logo from a sample of PBLT-40 Precision Board HDU.  You can get settings info below.

Settings Info:

  • 40HP Pump
  • .0010 Orifice Nozzle
  • .0021 Diameter Mixing Tube
  • 120 grit Barton Garnet Cutting Media

omax

As you can see, waterjet cutting is definitely a viable option for those looking to cut intricate designs in Precision Board. It produces no burn or char marks like a laser or plasma cutter would, and it can be used with any density or thickness of material.  Head over to our YouTube Channel to view a video playlist of Precision Board HDU being waterjet cut by various industry machines.

ABOUT OMAX

Based in Kent, Washington, OMAX Corporation is a global leader in advanced abrasive waterjet systems that cut virtually any material and thickness with unmatched speed and accuracy. Owner of the OMAX, MAXIEM, GlobalMAX, and ProtoMAX brands, the company provides a comprehensive selection of JetMachining Centers that feature intuitive software controls and incorporate the most efficient pump technology available. In developing its machines, the company designs, manufactures, assembles and tests components as a complete system to ensure optimum performance. The company also has the most comprehensive service and support network in the waterjet industry to keep its customers ahead of the manufacturing curve.  You can visit their website or call them at 800-838-0343.

ABOUT COASTAL ENTERPRISES

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane sign material that is particularly effective for making professional-looking indoor and outdoor dimensional signs.  It is a closed-cell rigid substrate that does not rot, warp or crack.  You can request free samplesget a quote or sign up for periodic newsletters packed with helpful information.

 

 

 

 

 

This Faux Wood Precision Board HDU Sign was Hand-Carved!

Andrea Craig is the Lead Designer for JH Signs & Designs. Her client, True North Salon & Spa, wanted an outdoor woodsy feel to her sign, but without the hassle of frequent maintenance due to the harsh Minnesota weather. She decided to go with a sign that looked like wood, but would last a lot longer and require minimal upkeep. Andrea designed a faux wood sign using Precision Board HDU. She likes that she can get the wood look while avoiding issues of staining or rot. Read on to see how she achieved a faux wood look on high-density urethane with hand-carving tools and different types of paints.

faux wood

Andrea tells us, “we had some direction from the client and this was the 8th or 9th option. She really wanted the state of Minnesota to be part of it and we started with that in the background. We ended up putting it as the ampersand in the words.”  She added, “We wanted the outdoor feel without being too much outdoors and we really wanted her name to be readable.”

For Andrea, the biggest reason for using Precision Board HDU and making it look like wood was the maintenance factor.   “With real wood you have staining and longevity issues.  With HDU, you have the ‘it doesn’t rot’ factor.”  She added, “being in central Minnesota, you get a little north of us, you can get all kinds of real cool rough cut wood, but it needs maintenance.  Our client didn’t want to have to keep updating it every few years.”

Craig used PBLT-15 Precision Board high-density urethane.  She took two sheets cut to 48″ x 56″ and then glued them together. From there she used a pattern she had made to cut the top and bottom of the HDU to look like individual boards.  All the work was done by hand with a Dremel and various carving tools.

Outside of using a straight edge ruler to draw the straight lines indicating where the boards were supposedly separated, the rest of the patterns were all hand carved.  “I printed out a couple different wood patterns for reference,” she says.  “I didn’t want the ‘wood’ to look all the same.”

Andrea used Ronan Fast Dry Blockout White to prime the HDU.  She then used a mixture of 1 Shot Medium Brown, Ronan Black and Ronan White mixed to create the charcoal gray base color.  “From there I used different shades of light browns and grays to give each board a different color. I then layered different shades with a dry brush technique on each board to give depth and variation,” she added.

To finish off, she made a wash that was really thinned down to bring out the colors and enhance the wood grain.  After that, a Rustoleum Matte Clear Enamel spray was used to take the gloss off and make it more realistic with a matte texture before the metal went on.

The middle layer is actually an 1/8th inch poly metal with an Avery Supreme Wrapping Film Brushed Titanium wrap on it to make it look like metal without actually being metal.

The letters are laser cut acrylic from Gemini, stud-mounted with additional standoffs to get them off the metal a little bit more.

Total project time was about 8-10 hours to fabricate the entire sign and about two hours of hand carving time for the faux wood HDU portion of it.

Andrea has been using HDU off and on over the last thirteen years and her current boss has used it for at least 20 years.  She says, “with wood, you can have a vision, but not find what you’re looking for.  With HDU you can get the look you want.  It really opens the door to creativity.”  She says, “don’t be afraid to play with it.  You have to think outside the box. Pretty much nothing is off limits.”

faux wood

ABOUT JH SIGNS & DESIGNS

JH Signs & Designs is a small progressive company that believes that image is everything. “If your business looks good, business will be good.” They stand behind their products and have a firm belief that if you treat the customer right and have a great product, you never have to worry about having a happy customer.  They have been making and installing signs in Perham since 1999.  Trust the professional staff at JH Signs & Designs to use the best materials that will last and make your business have the professional image to guide your customers to your door.  You can visit their website or call them at (218) 346-7446.

ABOUT COASTAL ENTERPRISES

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane sign material that is particularly effective for making professional-looking indoor and outdoor dimensional signs.  It is a closed-cell rigid substrate that does not rot, warp or crack.  You can request free samplesget a quote or sign up for periodic newsletters packed with helpful information.

Kern Laser: Settings for Laser-Engraving Precision Board HDU

We often get asked if Precision Board HDU can be cut with a laser jet.  Absolutely!  To show what kind of fine detail can be engraved into our material, we reached out to Kern Laser and asked them to laser cut something cool into a sample of PBLT-20 Precision Board HDU.  The results are spectacular and can be seen in the video below.  Read on to get settings information and learn more about laser-engraving of Precision Board high-density urethane with Kern laser cutters.

Kern Laser used their OptiFlex 400 Watt laser cutter to engrave the 3D image of a lion into our 20lb Precision Board HDU.

The OptiFlex is Kern’s flagship high performance laser system. The HyperDual motion package installed on the OptiFlex is setting the standard for large format laser cutting and engraving machines. This improved motion system features a rack and pinion design and powerful servo motors at each side of the laser table. Cut acceleration rates are up to three times faster with a 100{afbea94bd31582343c3017644f03ec8d7d8fa2386ecb82c250661e06c0c6e111} increase in top end vector speed. The X axis has also been upgraded with twin linear rails and a thicker steel reinforced belt.

Adam Voigt, Marketing Coordinator with Kern Laser, said “watching the laser create contrast and precision depth in this material was great.”  He added, “this is a neat application with a laser source.”

You can check out the specific settings that Kern Laser used below.

Settings Info:

  • 50{afbea94bd31582343c3017644f03ec8d7d8fa2386ecb82c250661e06c0c6e111} Power
  • 60 Inches Per Second (Engraving Speed)

Lasers can be an effective means of cutting, engraving, and marking various materials. High power, high-wavelength Carbon Dioxide lasers are widely used for material processing, namely for their versatility and relatively low cost as compared to solid-state laser systems. CO2 lasers are ideal for projects that require cuts or engravings so precise that they prevent the use of hand tools, or even a CNC router.

Precision Board HDU from Coastal Enterprises can be laser-engraved with great results and without worry about the toxicity of the fumes.  Universal Laser Systems conducted tests on the effluent created from laser cutting several different densities of Precision Board and indicated that, “the effluent stream is primarily composed of carbon monoxide, acetone, propene, and acetonitrile. The concentration of the detected compounds did not exceed their respective OSHA PEL at any level of filtration during this study.”  Permissible Exposure Limits (PEL) are federal regulations that dictate safe chemical exposure levels.  You can read more about laser-engraving of Precision Board HDU HERE.

To watch the full video of the laser-engraving from start to finish (14 minutes), head over to our YouTube and watch it HERE.

ABOUT KERN LASER

Kern Laser Systems was founded in 1982 by Gerald Kern, with the main objective to design and manufacture top quality industrial laser cutting and laser engraving machines to meet demanding production schedules. The company headquarters are located in the beautiful lakes country of Minnesota. The facility consists of a modern 50,000 sq. ft. building with 30 full-time employees.

Kern Laser Systems started by supplying motion systems for the existing computerized rotary engraving machines. As the sealed CO2 lasers became commercially available, Kern incorporated its motion package with the laser, developing a complete turnkey laser cutting and engraving solution. Kern’s vision has always been to manufacture laser systems that will fit the customer’s needs, at an affordable price, with the versatility to suit a variety of industries.

Today, Kern Laser Systems is proudly owned and operated by the first and second generations of the Kern family. Our goal moving forward is to constantly improve our products, improve processing times, and continue to offer our customers the best customer service in the laser industry.  You can visit their website or give them a call at (888) 660-2755.

ABOUT COASTAL ENTERPRISES

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane sign material that is particularly effective for making professional-looking indoor and outdoor dimensional signs.  It is a closed-cell rigid substrate that does not rot, warp or crack.  You can request free samplesget a quote or sign up for periodic newsletters packed with helpful information.

Creating Faux Stone Artifacts with Precision Board HDU

Coastal Enterprises, manufacturers of Precision Board HDU, is proud to host guest blogs written by some of the signage industry’s biggest movers and shakers, posted to the Precision Board Blog.  This guest blog is written by Dan Sawatzky with Imagination Corporation in Chilliwack, British Columbia, Canada.  This month, Dan tells us how he used PBLT-30 Precision Board HDU to create ‘artifacts’ (in this case, faux stone statues) for the North Star suite of the Hazelnut Inn.

artifacts

In Dan’s own words…

The website of the Hazelnut Inn describes the North Star Suite thus…

Local lore holds that the North Star was once the home of Temperance Longbottom. An eccentric explorer, Ms. Longbottom gathered artifacts and curiosities from every mythical corner of the world and built her estate around them.  Spend the night in the captain’s quarters of an ancient sailing vessel. Relax in a tub for two. Curl up by the fireplace. Explore the lush private garden, filled with whimsical artifacts. Staying in the North Star is simply a delight.

With this legend in mind we are busy creating the many ‘artifacts’ to be housed there. Two statues are among this collection and they are in construction currently in our studio. We decided the perfect medium would be PBLT-30 Precision Board HDU. For the basic shape Peter downloaded two 3D models from the web. These were imported into EnRoute and sliced into sections two inches thick. The two statue slices filled two full sheets of Precision Board. Since we planned on doing the bulk of the modeling ourselves, and in the process modify the statues considerably, we used a 3/8” bullnose bit with a 50{afbea94bd31582343c3017644f03ec8d7d8fa2386ecb82c250661e06c0c6e111} overlap. The reliefs were pretty rough and basic but provided exactly what we needed.

These slices were then glued up using PB Fast Set. A steel frame was embedded with two heavy duty threaded steel rods protruding out of the back. These will go through the exterior of the wall to be securely bolted to the interior framework of the building. We used plenty of course threaded screws as we assembled the Precision Board, countersunk to hold the material in place while we finished the piece. After using some sculpting epoxy to fill screw holes and apply other details, Peter used a die grinder to surface and shape the model. Some portions of the statue needed to appear broken, and by using a chisel and brute force, Peter did just that. The result was very convincing!

artifacts

The first statue is now in the painting stage with base coats applied and already looks pretty fabulous! By the time we finish the paint it will be impossible to tell from a real stone statue.

Sawatzky’s Imagination Corporation is a small family company that specializes in the design and creation of dimensional signs and environments. They tackle projects of any size from small signs to entire theme parks. Their work has garnered numerous national and international awards.

Dan Sawatzky is best described as a creative force and visual storyteller extraordinaire. His art career spans almost fifty years of magic. Dan’s passion is to design and create imaginative places that take people from the normal world to a setting of delight and wonder.

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane sign material that is particularly effective for making professional-looking indoor and outdoor dimensional signs.  It is a closed-cell rigid substrate that does not rot, warp or crack.  You can request free samplesget a quote or sign up for periodic newsletters packed with helpful information.

How Chip Load Factors into CNC Router Speeds and Feeds

We often get asked about optimal speeds and feeds settings for CNC routing of Precision Board HDU.  While there is a lot of great information on our website about feeds and speeds, what doesn’t get talked about as much is something called “chip load”.  Chip load can be defined as the size or thickness of the chip that is removed with each flute per revolution.  There are many factors that go into calculating chip load, so we’ve put together this blog with information from router bit manufacturer LMT Onsrud and CNC manufacturer AXYZ Automation Group.  Using the information in this blog, and with a little experimentation, you will be able to dial your settings in to achieve greater CNC efficiency when routing HDU.  Clean, sharp edges, a smooth cutting surface and potentially shortened cutting time are all benefits of optimized CNC router settings.

chip load

LMT Onsrud

LMT Onsrud is a premium cutting tool manufacturer servicing the metal working, composite, wood and plastics (HDU) industries.  Their tooling can be found within various industrial markets – aerospace, medical, composites, plastics, woods – and are used in making the products you use on a daily basis.

The proper cutting tool used with speeds and feeds information lets you achieve optimum chip load. Proper chip load allows the cutting tool to move in and out of the material quicker, leading to more efficient CNC machining.

You can optimize your chip load by setting the feed rate and cutter speed to yield the largest chip that produces the desired surface finish. Precision Board HDU is non-abrasive, which also prolongs tool life.

Here’s a useful formula:

Chip Load = Feed rate/ RPM x # of flutes

To increase chip load:

Increase feed rate
Decrease RPM
Use a cutter with fewer flutes

To decrease chip load:

Decrease feed rate
Increase RPM
Use a cutter with more flutes

Check out this video from Onsrud where they explain in more detail how to calculate speeds and feeds.

They reference a chart in the video with formulas to calculate chip load as well as speeds and feeds.  You can view a version of that below.

AXYZ Automation Group

AXYZ Automation Group is a leading global manufacturer of CNC router systems and CNC knife systems. Designed and built at their state-of-the-art factory in Canada, AXYZ CNC routers are supplied and supported through a global network of sales and support offices and authorized dealers. With more than 366,918 standard machine configurations, AXYZ specializes in matching machinery to customer’s unique needs and budgets.

They have an excellent website with valuable information on CNC routing.  You can find that resource HERE.

The following information is from an article of theirs on feeds and speeds and chip load.

Calculating Feeds and Speeds

There are certain parameters that must be considered, before setting up any file for cutting if you are to accomplish the finish and accuracy required.  One of the most important of these factors is the Chip load per Tooth (Cpt).  Chip load can be defined as the size or thickness of the chip that is removed with each flute per revolution.

When material is machined the cutter must revolve at a specific RPM and feed at a specific feedrate to achieve the proper Chip load. There are also several factors to be considered when choosing the proper RPM and feedrate.

The feed rate used depends upon a variety of factors, including power and rigidity of the machine, rigidity of part hold-down, spindle horsepower, depth and width of cut, sharpness of cutting tool, design and type of cutter, and the material being cut.

To obtain the optimum Chip load, we must consider the variables listed above, along with the machine and materials we intend to cut.  This will help us find the best feed rate and RPM for any given tool and material.

One thing to remember is to make chips not dust. Chips will help by removing the heat produced in the cutting process thus increasing tool life and improving edge quality.

chip load

Feed rate is calculated using the following equation:

Feed = N x cpt x RPM

N – number of cutting edges (flutes)
cpt – chip load (chip per tooth) is the amount of material, which should be removed by each tooth of the cutter as it rotates and advances into the work. (mm per tooth)
RPM – the speed at which the cutter revolves in the spindle. (Revolutions per minute)

We will now break down the relationship between the Feed rates, number of cutting edges, chip load and RPM. For most materials there is a recommended chip load.

If you are running at 18000 RPM using a 25mm endmill with two flutes, and a recommended chip load of 0.1 mm/tooth:

Feed = 2 x 0.1 x 18000 = 3600 mm per min

If the RPM were increased to 24000 RPM the new feed rate would work out to be:
Feed = 2 x 0.1 x 24000 = 4800 mm per min

chip load

Based on this mathematical equation, as RPM increases, feed rate will also increase if all other settings remain the same.  If the number of cutting edges changes, however the feed rate will either increase or decrease depending on the whether the number goes up or down.  The same applies to chip load if the recommended chip load is 0.1 mm/tooth the RPM, feed or number of cutting edges may go up or down to maintain the required chip load.  Therefore if chip load remains the same, and feed rate increases, either the RPM and or number of cutting edges must increase to maintain the recommended chip load.

When calculating the feed rate for any material the chip load is therefore one of the most important factors to be taken into account because the chip load determines the amount of material that each tooth will remove, plus the load that each tooth will have to take.  Another factor that affects chip load is the diameter of the cutter.  A larger cutter will be able to handle a larger chip load.

No of teeth cpt (mm) Feed rate (mm per min)
at RPM
18000 21000 24000
1 0.1 1800 2100 2400
2 0.1 3600 4200 4800
3 0.1 5400 6300 7200
1 0.4 7200 8400 9600
2 0.4 14400 16800 19200
3 0.4 21600 25200 28800

Therefore depending on the diameter of the tool, if the RPM and number of cutter edges stay the same chip load will increase with a larger diameter cutter, thus the feed rate will also increase.  When machining softer materials or using a stubby router bit the chip load can be increased.  If an extra long router bit is being used, the chip load should be decreased.

For most material that you will be cutting on an AXYZ router table you will typically set the RPM between 18000 and 24000, and adjust your feed rate to obtain the required results.  On an AXYZ router table we use spindles that produce a maximum of 24000 RPM.  The speeds and feeds chosen can be affected by the horsepower of the spindle being used (horsepower varies from 3Hp to 10 Hp).  At higher horsepower you will produce more torque thus allowing the machine to run at a variety of RPM’s (torque drops off as the RPM is reduced).  For most application we typically work in the 18000 to 22000 RPM range.

Typical Chip Load Values for Various Size Cutters

Tool Diameter Hard Woods Softwood / Plywood MDF / Particle Board Soft Plastics Hard Plastics Aluminium
3mm 0.08 – 0.13 0.1 – 0.15 0.1 – 0.18 0.1 – 0.15 0.15 – 0.2 0.05 – 0.1
6mm 0.23 – 0.28 0.28 – 0.33 0.33 – 0.41 0.2 – 0.3 0.25 – 0.3 0.08 – 0.15
10mm 0.38 – 0.46 0.43 – 0.51 0.51 – 0.58 0.2 – 0.3 0.25 – 0.3 0.1 – 0.2
12mm and over 0.48 – 0.53 0.53 – 0.58 0.64 0.69 0.25 – 0.36 0.3 – 0.41 0.2 – 0.25

Even though there are formulas for calculating feed rates you will find that optimum feed rate will be determined from experience.  You will typically start off with the calculated feed rate.  Under ideal conditions it is usually suggested that the actual feed rate be set to approximately one-half the calculated amount and gradually increased to the capacity of the machine and the finish desired.

Once you have determined what feed and speed to start with, there are other factors to be taken into consideration. The next thing to be considered is the direction of cut, which is the direction the cutter is fed into the material.  Conventional milling or cutting forward is the most commonly used method.  With this method the work is fed against the rotation direction of the cutter.  The other method is climb milling or cutting reverse.  For this machining method the workpiece and the machine must be rigid.  The AXYZ router machine is such a machine.  When machining non-ferrous materials, climb cutting should be used to achieve a good finish.

Another factor is depth of cut.  Depth of cut will effect edge finish as well as tool life.  You will have to adjust your depth to achieve the desired results depending on the type of material and size of cutter.  Usually a depth of cut that equals the radius of the cutter is a good starting point when cutting non-ferrous metals.

Conclusion

By experimenting with these different speeds and feeds settings, and using the chip load formula that works best for you, it’s possible to maximize your CNC efficiency.  Always remember to make chips and not dust.  This can potentially speed up your cutting time and help you to achieve clean, sharp edges and a smooth routing surface on your HDU.  Trying a variety of cutting tools and settings will also add life to your CNC machine and save wear and tear on your cutters.  When in doubt, consult the manufacturer of your CNC for best practices on chip load for your particular CNC machine.

About Coastal Enterprises

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane material used extensively in the tooling industry.  It is a closed-cell rigid substrate that does not rot, warp or crack.  You can request free samplesget a quote or sign up for periodic newsletters packed with helpful information.