Star Wars Coasters

This looks awesome, great job! :hushed: You produced great results faster than anybody else here, I think. :slight_smile:

The little gaps where you can see the glue might be from making it a little too deep or are inaccuracies with the CNC. My first large inlay had major problems because my CNC wasnā€˜t square. Since the inlay is mirrored, 0.25mm out of square ends up being 0.5mm in the end. Jamie had some kind of rotating idea but I never understood that. :smiley: Itā€˜s somewhere in an old thread.

I used to plane it down with the CNC, I did it with the bandsaw the last time, then sanded it with my homemade drum sander. With the bandsaw wasnā€˜t unproblematic either, but less hassle than programming a clearing toolpath. I am going to build a jig where I can clamp round objects to put through bandsaw and drum sander some day. :slight_smile:

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I think my main problems were:

  • Inconsistent Z-height. The 1/8" bit I used to hog out the majority of the wood cut visibly deeper than the 30 V bit.
  • Fuzzies - The feeds and speeds are wrong on that V-bit (itā€™s new.). I need to tune that in a bit. (I had to scrape the fuzzies, and I did chip some of the thinnest areas.) Also think I need a finishing pass strategy.

Itā€™s also funny - Iā€™m starting to think a little more like someone operating a CNC. But for small test projects I often overlook the details. So for these tests, I did 1 coaster at a time, and 1 inlay at a time. Then clamp overnight, then plane, etc.

I enjoyed it enough (and these would make great stocking stuffers with a variety of graphics) that I think Iā€™ll make a fixture so that I can plane the materials to uniform thickness, then carve both the items and the inlays at the same time with the same z-height probe. Iā€™ll try to send pictures if I get the fixture made this weekend (mainly for suggestions from the experts :grin:.

Question: When I think about a V-bit, the speed the flute engages the wood would be max at the top of the V (never used), and lowest at the tip (always used). Do I need to spin a V-bit faster to compensate? Or are there other tricks for a less fuzzy result from a V-bit?

Thanks all.

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Very neat, really interested in how that turns out. Sleight height differences really are not helpful. I only started to stop eyeballing stuff with theses coasters, because I was mad that it didnā€™t work too well. :smiley:

I never really thought about it, but I just run the V-bit by earā€¦ A little slower than the other endmills. :slight_smile: I can adjust on the fly digitally though.

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@Tokoloshe What have you found to be the best bit for doing shallow inlays like this?

Iā€™m back home now and am about to start playing with this a bit.

At my disposal currently, I haveā€¦

a 45Āŗ like this
image

Some tapered ball nose like this
image

and Some V1 45Āŗ bits

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Phew, it really depends. For the coasters it wouldnā€™t matter since you are setting a max depth anyway, for things like fonts I usually use my 60Ā° over my 30Ā° or 10.2Ā° because then it is just a lot quicker because it doesnā€™t cut as deep but the full width in one go.
For the tiny birds I used the 10.2Ā° with the round nose, you can just force them together and those 0.25mm round at the tip can safely be ignored. :smiley:

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Iā€™ll probably try to just do some simple shallow shapes first before I do anything too complicated, but I have some more complicated Christmas gifts that I need to make coming upā€¦

Thanks for the helpā€¦

Iā€™ll post somewhere if I do anything useful :slight_smile:

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Also post if you donā€™t do anything useful so we can help make it better. :smiley:

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