diff --git a/README.md b/README.md index bd196a241fd19a13c02a8dc9e082d7a731e27753..222b3d0fb2263c8064d0804010ce53d97557ac9e 100644 --- a/README.md +++ b/README.md @@ -1,3 +1,43 @@ # emboss-today -Rapid manufacturing of embossing tooling for permanently marking thin plastic. \ No newline at end of file +Rapid manufacturing of embossing tooling for permanently marking thin plastic. + + + + + +## need +As part of our covid-19 face shield production efforts, we need to permanently mark units that end up in hospitals with a few basic identifiers: a manufacturing batch number and a shortened URL for assembly instructions. The Zund needs to spend its time cutting rather than marking, and doctors have complained about the smell of laser-engraved text. + +## rapid embossing tool manufacturing +Several letters were cut out of 0.5 mm Cu stock using our nanosecond laser micromachining system: + + + + + +The coupons were punched out but the letters were left in place for electrochemical deburring in 14M H3PO4, ~1 minute, 3 VDC: + + + +Letters were then carefully punched out using a sharp probe under the Lynx Evo inspection microscope. Each 6 mm letter was sanded on two opposing sides to remove remaining cut debris in preparation for soldering. A piece of 0.02 mm Cu sheet was cut with sheet metal snips, fluxed, and the letters carefully soldered on using SAC305 solder: + + + +The tool was cleaned with IPA and attached to a desktop rack-and-pinion-style press using double-sided tape: + + + +A piece of silicone rubber was similarly attached opposite the tool to prevent bottoming out on the metal platen: + + + +The press was tested 100 times on a scrap of 0.5 mm PETG: + + + +The 101st test was performed on a scrap of 0.75 mm polycarbonate: + + + +Further cycle testing should be done to test long-term durability. diff --git a/img/emboss-today_101st.jpg b/img/emboss-today_101st.jpg new file mode 100644 index 0000000000000000000000000000000000000000..2e63323f9dbb37485dab2442dbb3abc1262be978 Binary files /dev/null and b/img/emboss-today_101st.jpg differ diff --git a/img/mfg_100_tests.jpg b/img/mfg_100_tests.jpg new file mode 100644 index 0000000000000000000000000000000000000000..5271f527131e40c46c17f46d136c71d378710ab0 Binary files /dev/null and b/img/mfg_100_tests.jpg differ diff --git a/img/mfg_press.jpg b/img/mfg_press.jpg new file mode 100644 index 0000000000000000000000000000000000000000..bcb418c213494aecf365d59d4b6f97bf88deb188 Binary files /dev/null and b/img/mfg_press.jpg differ diff --git a/img/mfg_tool.jpg b/img/mfg_tool.jpg new file mode 100644 index 0000000000000000000000000000000000000000..3606cb5468fd3b338bcb8fe76f83bc8a5860e971 Binary files /dev/null and b/img/mfg_tool.jpg differ diff --git a/img/oxfording.mp4 b/img/oxfording.mp4 new file mode 100644 index 0000000000000000000000000000000000000000..62d102723bdffcc1a3f5b15968e4a505bafd0d82 Binary files /dev/null and b/img/oxfording.mp4 differ diff --git a/img/tool_deburr.jpg b/img/tool_deburr.jpg new file mode 100644 index 0000000000000000000000000000000000000000..8e409fd3838f92331ebc42585795554b6c6b4c27 Binary files /dev/null and b/img/tool_deburr.jpg differ diff --git a/img/tool_in_oxford.jpg b/img/tool_in_oxford.jpg new file mode 100644 index 0000000000000000000000000000000000000000..a4bfc672b62a84c1e62ead2bcd0fe5c354cabaee Binary files /dev/null and b/img/tool_in_oxford.jpg differ diff --git a/img/tool_soldered.jpg b/img/tool_soldered.jpg new file mode 100644 index 0000000000000000000000000000000000000000..f1a1da9641b862365cbf2ca5b9d11470f867238f Binary files /dev/null and b/img/tool_soldered.jpg differ