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looking for a machine capable of cutting solid polycarbonate sheets 1-5mm

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rstofer:
Part number '1', among others, has a very square transition in the corner.  Unless you remount the part vertically, you can't cut that with a mill.  Can you stand a 1/16th inch radius of a 1/8" cutter diameter?

A simple mill is 2-1/2 D (as opposed to 3D, debatable) in that it locates x and y and cuts down to a depth.  A 2D CAD program is adequate with a post processor like CamBam to handle the depth.  CAD -> CamBam -> Mach3 (machine control).

fourfathom:

--- Quote from: rstofer on April 09, 2024, 07:00:48 pm ---Part number '1', among others, has a very square transition in the corner.  Unless you remount the part vertically, you can't cut that with a mill.  Can you stand a 1/16th inch radius of a 1/8" cutter diameter?

--- End quote ---
No reason not to use a 1/16" dia bit (or similar  metric size). They are of course more fragile.

thm_w:
You might consider getting the 3D scanner and a 3D printer first, then use that to print a prototype part.
After you are sure it works, send it out for someone else to make.

The cost for someone else to make these parts for you will not be that high, here is a US example, I'm sure there are many in the UK: https://sendcutsend.com/

DiTBho:

--- Quote from: rstofer on April 09, 2024, 07:00:48 pm ---Part number '1', among others, has a very square transition in the corner.  Unless you remount the part vertically, you can't cut that with a mill.  Can you stand a 1/16th inch radius of a 1/8" cutter diameter?

A simple mill is 2-1/2 D (as opposed to 3D, debatable) in that it locates x and y and cuts down to a depth.  A 2D CAD program is adequate with a post processor like CamBam to handle the depth.  CAD -> CamBam -> Mach3 (machine control).

--- End quote ---

they are still raw parts, I have to make a third piece, assemble them on an axis, then chamfer and round further
I don't have an exact impression of the quarry, only a fuzzy idea, and I'm going by trial that "somehow" fit, with two or three templates, taken in three different points

in turn, I have to insert a very thin tip inside the hollow (the black piece in the pic), to try to make the excavation as uniform as possible.
90% is already ok, just not perfect.

it's all hacking work on parts made for a bicycle

DiTBho:


This is instead a piece that I built for a particular computer (not a PC)
It has a thickness of 5mm, I drilled it and opened a rectangle to be able to mount a 2x16 character LCD
Opening that rectangle was a bloody hell, all done with a small iron file, it took me nine hours!!!

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