Pressed / punched aluminium - how / what kit?

[julianf]

I currently cnc mill / engrave parts like the one below, but, as mentioned elsewhere, im setting up to print them.

I can saw cut the exterior of the panel, but i dont have a solution for the holes.

A drill is too messy - without more attention than i want to spend, the holes are not clean, nor is it accurate enough. Parts like these on larger runs are, im sure, pressed. The edges of the cuts on commercial panels ive looked at certainly show the small smooth section at the top of the cut, and then the fracture, as is typical of pressed metal.


...but i just dont know about doing it!

In an ideal world, setting all the punches in configuration and doing all the holes in one pass seems perfect, but i suspect that may be beyond the scope of my workshop?

Can anyone advise?

 

[gaz_moose]

fly press???

 

[julianf]

would work for 1-offs, but i can cnc them

im really looking for a quicker option than the cnc mill.


...but then, if i could do all the holes in one go on a fly press, that would work, for sure - is that what you meant?

 

[mike 109444]

I see no image..... ??

 

[julianf]

Better?

 

[julianf]

Ive been calling water jet places today, but they quote tolerance at +/- 0.2mm - which seems huge compared to what i was expecting.

 

[mike 109444]

Think you would have to look to CNC punching. It would punch one hole at a time but tool changes and movement would be much quicker that by hand and I would not expect you to be able to fly press more than one hole at a time!
+/- 0.2 mm does not sound to bad for a panel for switch gear/controls. You are not comparing to your cnc milling are you? as that may be set up tighter on tolerances.