[trialanderror]

What tool and process should I use to make these 2 cuts?

If I use a standard end mill won't the edges be a bit round?

I am assuming that for the hex one I drill the hole first and then endmill the sides with a normal size tool and then pick a small tool to make the edges square?

And for the square one I just end mill everything and then make the edges square with a smaller end mill.

Are these the normal processes for doing this type of work?

Cutting into 6061 aluminum if it matters

[txcncman]

You are correct. You can't mill inside vertical corners square. There is a possibility of broaching, depending on the part application and machines available. Getting a perfectly sharp inside vertical corner is almost impossible. Engineers that understand this will allow some type of radius or allow over-cutting in corners.

[skmetal7]

if the corner needs to be square, you can put "mickey mouse ears" at each corner. You drill a hole somewhere outside the corner to allow for clearance, then mill the pocket.

[fizzissist]

Stereolithography.
Coat the plastic to fill the pores, then make a latex mold.
Fill the mold with wax, then make a plaster mold.
Fill the plaster mold with melted 6061 (use the HIGH setting on your stove) and
let it cool.
Break the plaster off and there's your part.

[trialanderror]

thanks will give that a try

[roninB4]

This is a candidate for conventional EDM (sinker/ram) . It can be accomplished a couple of other ways but EDM is the simplest, most accurate means of creating both shapes.

[RICHARD ZASTROW]

Find somebody with a "cherrying" attachment on a Bridgeport. That's made to do exactly what your asking to clear corners.

See, it pays to be an old fart.LOL

Dick Z

[fizzissist]

This is a candidate for conventional EDM (sinker/ram) . It can be accomplished a couple of other ways but EDM is the simplest, most accurate means of creating both shapes.

Hadn't thought of EDM... Good idea!
Use a wire for the outside and holes, 2 chuckings, then a sinker for the profiles/pocket.