i'm trying to build a simple way to make templates for faceplates

[versuviusx]

i'm trying to build a way i can build a template for facepltates that are rackable. the end result will look like this

http://cgi.ebay.com/Bellari-RP583-S...DVWQQrdZ1QQcmdZViewItem?hash=item160037891015

basically it will be a punch. instead of using a CNC milling machine i would like to make something that allows me to punch all the holes in the front faceplate. so i can make DIY projects for people. i picked up a hole puncher for punching holes in paper and i was hoping i could find someone who could help me make such a device that would act like the hole puncher except it would put 10-12 holes in a sheet of aluminum 19"X3.5". i think it can be done. but i'm certainly going to need some help. any ideas would be great.

 

[unclesyd]

You didn't mention anything about quantity but if you are talking quantity you might want to give the UniPunch people a call. I've seen as little as three of these punches run using a hydraulic press.

http://unipunch.com/products/standard_shapes.asp

 

[ajack1]

You do not mention quality or quantity and what is the thickness? Will all parts be the same or will there be variants on the same theme?

The units unclesyd mentions are good but you cannot have holes “close together” they are also fairly expensive and you will need to create a jig to line them up, they usually have a 6mm / ¼” dowel in the lower face, you will also need a press of some kind.

Another option is to have a cheap press tool made, probably cheaper than the units above but this will only produce one variant.

If the material is thin consider a shim punch ask in any toolroom to see one. Basically it is two plates that line up on dowels with a series of punches and holes that you manually line up and hit with a mallet. Very low tech and not extremely accurate but cheap and flexible, you could of course make a unique part to produce each variant.

The final option I would suggest is a drill jig (if the material is thicker) much along the lines of the shim punch. The part is located between to plates and a series of dowels with a hardened drill bush on the centres you wish to drill. A slow process but cheap and accurate and you only need a drill press or pistol drill.

 

[dvd]

If you are doing custom, one-of-a-kind work then you really need to get your panels laser cut. Just supply a cad file to the vendor and they cut it, cheap. Tooling can't compete costwise.

 

[versuviusx]

well currently the quantity is undecided. i would say anywhere from 50-100 for now. and also i like the idea of a drill jig. it seems cheap and accurate. what would be the best material to make the jig. i don't think wood would be the best material as i would like my jig very accurate. also if i did go the laser cut route who would be a good vendor for such services?

 

[ajack1]

I would consider using mild steel with hardened bushes or using a low grade tool steel that is hardened, for the volumes you are talking about either would do the job, it really depends on what facilities you have available to you.

Laser /water jet may be cheaper for such low volume and would be accurate as for a vendor I would look locally so that depends really where in the world you are.

 

[versuviusx]

are there any online services where i could send the plates to to get a laser/water jet job?

 

[griffengm]

versuviusx,
Try mfgquote or Thomas Register. Both can help put you in touch with job shops who do what you seek in services.
Unipunch makes a good product that can be ganged to make several holes per hit but, in addition to the tools, you need a machine on which to run them, space to store and the ability to support maintenance and repair.
Ask yourself what you want to do - Dream up/design products and services OR make parts?

Griffy