Wood Mold

After the we tried the latex mold we decieded to go back to using the wood mold idea again.

But this time we decieded we'd give the mold a better shape.  So using adobe photoshop i created a rounded rectangle with the best compromise between edge radius and it's effect on the overall size of the device.  Then converted it to an HPGL file which could be used by the machine.

One problem arised when i went to mill the board.  The dpi i had used in adobe didn't translate properly to the dpi in the milling program.  So measuring the size of each i determined that a scaling factor would be needed of approximately .6  == ( size of printed drawing from adobe / size of milled drawing )

By experimenting with the scale factor and making a few cuts in a piece of plywood i determined the ideal scale factors.

Notes on Scale Factors:
    .566 = scale factor to use when you are trying to make a mold cutout
    .584 = scale factor to use if you want the piece which get's cutout to be the actual size of the mold.  (useful for making say a rubber mold)