Project of the week is an injected molded Tag Holder made of Red Cycolac ABS. These parts are roughly 8" x 5" x 1/2" and is used to hold and display some type of film, we do not know the application it was made for. This part has a slot through the top of the part that creates an undercut on this part to hold the film. Mold experienced some type of slide damage preventing the parts from being released from what the client told us. Mold was modified to mold the top slot to about a 1/2" deep and the center window was still molded open as pictured. Our task was to machine the inner window frame or slot depending on what you want to call it. We machined over 2550pcs until the issue was resolved and no longer needed.
One tool was used to for this project, a custom-made low-profile arbor and a high-speed steel 0.100" thick slitting saw did the trick. We used Mic6 aluminum plate for fixturing in order to hold down and protect the long edges from chattering. Due to the part size, we can only machine 2pcs per cycle per machine. Slot was 0.080" wide with a tolerance of + 0.020 / -0.000. This was not complicated to machine but when we first cut this part, we tried cutting with a 0.090" thick slit saw and being a deep slot it actual collapsed due to internal material stress. Part had to be machined in one pass due to the collapse of the inner wall it would cut the slot beyond its max tolerance if attempting a clean-up pass. We would like to thank our customer for allowing us to share this project with people who value the manufacturing talent that is out there... If you have similar projects like this and would like to receive a quote from us, please reach out to us for further information.