Electronics > Projects, Designs, and Technical Stuff
Square holes on aluminum.... how do you do it?
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duak:
It's neither here nor there but back in the 70's & 80's I could get sheet metal punched and formed locally on a CNC turret punch.  Here's a more modern example: http://www.vandf.co.uk/tooling/what-is-cnc-punching/  Outside of my personal snack bracket though.

Actually, back then it was an NC turret punch that read from paper tape and the vendor asked us if we could repair it.  Turned out a 4 bit counter driven by a crystal oscillator had died.  I really lucked out because the board had a bunch MSI chips on it  and I didn't have a schematic.
james_s:
I use a nibbler tool generally. Other times I drill a round hole that takes out as much of the material as possible and then square it up with a file.
bson:
If it's for prototyping, the best IMO is to design them in a suitable CAD tool and either 3D print or mill out of acrylic.  The same design files can then be used for manufacturing when you're happy.  I find 3D printing is much easier than milling, for modest sizes.  For a large panel milling is easier since it can be done in a single piece.  Even for a 1-off DIY project I'd still do this and have someone mill me prototype panels once the 3D ones fit and seem right.  You'll get a professional looking result you can show off and learn a useful and marketable skill.
coppercone2:
if its a big hole use a plasma cutter
james_s:
I still struggle to find an example of something that is 3D printed (on a hobby level machine) that doesn't look like crap. Milling out of acrylic can be ok but laser cut ABS is even nicer for panels IMO. I tend to build a fair number of one-offs though so hand machining aluminum panels is something I do fairly often. In the time it would take to draw it up in CAD I could just make the panel and when I only need one there's no advantage to having the CAD file.
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