Ok…
Using CC to create file of backing of the puzzle I followed the steps William created in a Facebook post.
I am using 1/8 downcut bit.
I took my letters using Arial Round Bold font and copied for two files. One for the letters of the puzzle and the other the backing. On the backing I used the feature ‘offset’ and added .035 to the outside and inside of letters then programmed for a conture pocket toolpath. I kept the letters the original size and did an outside cut for the pieces outside and left the defaulted offset in tool as is.
My problem is that the letters that cut on the backing stay as soon for the font. But the letters cut for the pieces round where it’s a corner. Can someone let me know what I am doing wrong! Thanks puzzle name.nc (38.5 KB) Puzzle Backing File.c2d (556.6 KB)
So I am doing attempt two at the backing. How can I fix this for the actual letters so they are round in those areas when they cut. Or is that not going to happen?
The issue looks to be that you are trying to create a 90 degree angle using a round endmill. It is possible on the negative, because the tool simply has to go past the edge in both directions. For the actual raised letter, the best you could hope for is to use a very small endmill to create a less noticeable curve. You are never going to be able to get it to cut a true 90. It will always leave a curve relative to the radius of your bit.
The simplest solution would be to just round the corners of your backing board to match the curve of the letters.
I’d suggest offsetting the letters or editing them with a Boolean operation or using node editing to address this (or just use a sharp chisel or gouge on the corners).
Offset inside your text by the radius of the cutter; then offset outside the previous offset by 2 times the radius of the cutter; then offset inside the second offset by the radius of the cutter. You now have the text in the original size with all corners (inside & outside) radiused to match the cutter. Use this for the letters and offset outside by the desired clearance for the backing.
The tip worked to do offset, inset, offset to remove the 90 degrees for the backboard. But now I am finding the raised letters now are cutting too skinny and the original I sent above (my test cut example) fits perfect and I unfortunately deleted that file.
