Ideas needed for mass production of original kit part

[Jaded Monk]

The original part was fabbed up by laminating 1 or 2 mil styrene sheets against a circular opening. The hole was later scribed and filed smooth. It is approximately 3" in diameter and 2" high.

I need ideas for how to mass produce this part for a lot no smaller than 10pcs. I don't have a pressure/ vacuum cast set-up and am not in any position to buy a pressure pot or venturi pump right now. I can cast, but I'm concerned about the thin wall.

I've already put up $230 in laser cutting and would much rather not have to figure out funding for another run.

PVC is out as the wall is much too thick. I checked TapPlastics but didn't see anything with a thin enough wall.

Unless... kit builders would be amenable to laminating the styrene themselves and scribing with a provided template.

So... any of you creative geniuses have any thoughts?

Cheers!

JM

 

[Raffles]

Cut it in half and cast?

 

[RICHIES ARMOR]

Lazer cut them in flat strips and then roll them up individually???

Your lazer cutting costs seem a bit high for that one item.

Richie

 

[Darth Lars]

Could the hole not be routed on a CNC mill? Construct a rig which would hold a tube section firmly in place during the process without warping it.

 

[LeMarchand]

Get is as a long tube and have the slots milled out, then cut or lathe the pieces in the correct size?

 

[Jaded Monk]

@Richie, the laser cutting costs were for 10 copies of a much, much, more intricate set of parts. I just don't want to shell out anything more at this point.

Raffles has it though. As ever, I was over-complicating things. This cylinder would have been glued to the inside of parts that I am already casting in halves. It will be such a simple matter to cut it in half and attach. Thanks!

JM

 

[exoray]

How thin are the walls? And how 'clean' does the final piece have to be?

From what I see i can be cast pretty easily...

It could also be rapid prototyped pretty reasonable, but the surface wouldn't be as crisp, nothing a quick sanding wouldn't take care of though...

Personally I would probably have a master rapid prototyped and then mold that if the cost was too prohibitive to have them all rapid prototyped...

 

[Sidewinder]

I'd make the original out of ally tube, mill out the slot. Assuming that the inside was not on show on the final product i would block off the slot with very thin plasticard. Then make a one piece mold using my pressure pot and pressure cast the parts. You'd simply need to trim out the thin skin on the hole on the castings then.
All this depends on how strong it needs to be what its for etc.

SAS