Iphone case prototype holddown (thinking cap required here!)

[myxpykalix]

I am working on a iphone case prototype for a company that i can't say too much about. This is not for one of those protective covers but something different.

What this basically entails is i am modeling all four sides of the internal structure and what i need to be able to do is create some type of jig that will allow me to hold the part in the same location in both a flat position and then on its sides and top and bottom to be able to cut the various slots and holes.

Just visualize laying an iphone flat and cutting a frame then laying it on its sides and cutting slots and then turning it straight up and down and cutting slots in the top and bottom.

Because both sides (L&R) would be on the same plane and Z zero to the center of the .25" thickness I would think some kind of fixed jig to hold it on its side then be able to flip it might work like a vacumn jig.

Then I think the same for being able to hold it upright to mill the top and bottom.
Anybody else doing anything similar in trying to hold thin material upright?:confused:

[CNYDWW]

Hey Jack,

4th axis should do the trick. If it's two thin at that point, pocket out a case for the "case" and pocket/mill through it.

Regards
Randy

[harryball]

I'm not completely sure I understand what you're trying to do Jack, but if I understand it then this might help...

I needed to machine the top of a 1/4" thick board. I put a 1/2" sacrificial board on each side to make a "sandwich" and mounted that upright. I was able to machine the 1/4" piece without vibration and chatter.

Hope that helps.

/RB

[myxpykalix]

Harry you are on the right track, i have to machine both the flat face of the material and the .25 thick sides and Randy's idea of using the 4th axis is a good one but i'm going to have to make it so it can hold the part in 3 different positions flat on its back, on its side, and on its bottom.

I think carving the 3 positions into some plywood and making a "sandwich" so i can flip the material for the various cuts is a good idea.

These ideas are taking my thought process to a whole different direction. I was thinking about rigging up vacum pods and jigs and this seems simpler.:D

[Brady Watson]

You want something similar to a Kurt vice to hold the thin edges up for machining. This is how it would be held accurately (with parallel bars) if it were metal.

A vacuum pod mounted to a piece of AL angle would also work.

-B

[genek]

jack some one is making a phone case out of wood that is on here.. you may want to work with them they have it already designed and producing it.

[myxpykalix]

Brady..I looked up Kurt vise but saw many different things did you have a specific model in mind?

Eugene i think what they had was a protective case that the phone slips into. This is something that takes the place of the original frame that the phone is housed in, but it wouldn't hurt to talk to that person and get some machining tips since i'm not looking to duplicate what they are doing.:)

[genek]

Jack check with Bill Palumbo.. the man was at the tide water camp.

[Brady Watson]

I have this one (http://www.use-enco.com/CGI/INSRIT?PMAKA=990-1019&CS_003=5341490&CS_010=990-1019) - It is probably out of your price range & the concept is what I was trying to convey - not the vice itself.

You can also use a wood vice on the end of your table to hold the part just like so many people have already done for making dovetail joints and other parts that need to be turned up on end.

-B

[billp]

Jack, Is this the kind of case you're looking into? John Haggerty has been building them for awhile- http://www.facebook.com/HaggertyWoodworking/photos_stream

[myxpykalix]

Brady, all i can saw is...:eek:

Bill John H is making some real nice cases but what i'm asked to do is different. If you took the front and back plate off your iphone you are left with a metal baseplate from the center of the phone. I am modeling prototypes for that center baseplate and not a protective cover for the complete phone.:D

[tlempicke]

Try machining your jig out of phenolic rather than wood. Much more stable and easy to cut.