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IndustryArena Forum > MetalWorking > MetalWork Discussion > "Disposable" Aluminum Alternative
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  1. #1
    Join Date
    Mar 2007
    Posts
    4

    "Disposable" Aluminum Alternative

    I'm going to be cutting a few molds for encapsulating some small circuit boards out of 7076 aluminum (encapsulation vendor's recommendation for material). But seeing about the cost of aluminum, I would like to do some 'fitment tests' before I actually cut aluminum.

    I'd like to find a material that I can cut with the machine and end up with a pretty similar finished product as far as dimensions go to what I'm going to end up with with the aluminum. But spend a lot less. Since I have a feeling it matters, I expect the final product to be milled out of 1"x6" (or possibly as small as 1"x4") bar stock.

    I was thinking of playing with MDF, but it sounds like that's got challenges of it's own (although it still is an option I guess).

    So, Ideas of something I can buy and use for testing which costs less per cubic inch than 7076 aluminum, and which is easy to work on the mill?

    I realize I might have to buy a few mills for this... I'm definitely open to that. One mangled block of aluminum can easily pay for a couple of mills.

    -forrest

  2. #2
    Join Date
    Aug 2010
    Posts
    0

    Well, besides MDF, which you mentioned, some other alternatives for 'fitment tests' might be: wax, phenolic (Richlite is one popular maker) and polyurethane foam board (Renshape is a popular maker).

    Phenolic and Poly board are going to be more expensive than MDF or wax, but with better edge retention and dimensional stability.
    The Manufacturing Reliquary
    http://cmailco.wordpress.com/

  3. #3
    Join Date
    Feb 2006
    Posts
    198
    I like to use HDPE to prototype my projects. It's cheap on eBay, machines very fast, and holds good tolerances.

    -Jim

  4. #4
    Join Date
    Aug 2010
    Posts
    0

    Quote Originally Posted by Kingjamez View Post
    I like to use HDPE to prototype my projects. It's cheap on eBay, machines very fast, and holds good tolerances.

    -Jim
    +1 on that. Good and cheap... can't say that about most things these days.
    The Manufacturing Reliquary
    http://cmailco.wordpress.com/

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