We had a few NDA projects over the holidays, and a couple that weren't. So I thought I would get started with the couple that we're allowed to share.
The first one was what should have been a simple one, but progressively took more time than I had planned on. Hey, it can happen!
A neighbor a few units down from us does major renovations, for some pretty big custom properties.
He had contacted us in hopes that we could match his custom trim profiles for a series of arched top windows in a huge house he was building.
"Sure, should be pretty quick" I thought out-loud...............
I took his trim profile, traced it onto a sheet of paper, and scanned it into the computer, and adjusted it for some minor differences. This clearly would be made from 2 pieces, as the machined out waste would be way too much!
Here's where it pretty much fell apart for me!
Due to the X and Y size of the window trim, versus it's relative skinny width, versus the resolution of Aspire on an entire 4X8 sheet of MDF, it didn't come out very well. On a 4X8 sheet, with the maximum 50X resolution (the highest Aspire reaches) it put a voxel pixel at around 1/16th of an inch. So couple that, with a .125" cutter, and you get a relatively rough piece of trim. Add to that, the long 3d machine time of multiple pieces of trim, and it all boils down to finding a better way to deal with this. The estimated machine time, including cutter changes, was 6 hours a sheet. PFFF.......
Aint nobody got tahm for dat!
So I was forced to re-think the process. I decided to go with many, many, many, single profile toolpaths, at the varying heights required.
WAAAY more computer time than I had first anticipated, but it got the machine time down to 45 minutes a sheet, and the trim was flawless!