The client of mine has giant 3d cad run machines. They look like the machines that they use on 'american chopper' to cut their 3d aluminum rims and such.
He makes aluminum and steel pieces for harleys and buells. I am 100% sure he can make just the barrels fairly simply. The whole blaster, I do not really know what will be involved.
The only real problem with it is that you will get some milling marks.
If you asked me, I would say your lookin gat a two piece blaster at least.
Barrel and grip.
And I believe you about the WOF templates, but theres more than goes into it than just 'putting in the dimensions'.
If his drawings are actual 'cad' drawings, and they are 'good' geometry, meaning no funky polys or open spines, they will be good to go.
I will get his contact information for you.
I had asked him about making saber hilts, and he said it was a piece of cake, but the high quality aluminum is pricey, and the harder it is, the more 'consumable' tools you go through.
Because I have never actually _done_ 3d cnc fabrication, I do not know exactly what he means, if its bits or what. I have howevef done the 3d work for the plastic molds for game controllers, and its fairly time consuming. But again, im no pro, and a pro could probably do it with much quicker.
I realize that WOF is very talented, and I have seen some of his designs, and they are great. I was only asking if they were truely cad cut ready drawings.
If I were to guess, your talking about 100+ in just aluminum each gun, depending on the quality you use.
What type alum are you thinking you want to use? Have you priced materials?
Pricing your materials would help you a lot when you talk to machinists.
Being able to say 'The handles can be cut in x pieces, from a 100mm x 300mm x 30mm piece of 2011 (not as strong as 2024 but cheaper), or 7075 (aircraft grade) and the barrell assembly from a alum tube 40mm diameter x 550mm long (Im just throwing numbers).
Total retail price of the aluminum is going to be roughly $93 per piece + shipping.
Then you find out 'how many cuts/passes etc it would take to make the shape.
The type of aluminum, also determines how smooth it will be, and how long it will take to cut it.
Heres some alum info for you to start with.
Next to steel, Aluminum is the most commonly used and commercially available metal. Its light weight and high strength-to-weight ratio make it a good choice for everything from aircraft to flashlights to jigs to just about anything else you can make out of metal.
Pure aluminum, primarily seen in the 1xxx series of wrought aluminum alloys, has little strength, but possesses high electrical conductivity, reflectivity, and corrosion resistance. For this reason, a wide variety of aluminum alloys have been developed.
OnlineMetals.com currently stocks six alloys of aluminum in various shapes and sizes: 2011 Aluminum (available in Hex, Round)
2024 Aluminum (available in Plate, Rectangle, Round, Sheet, Square, Tube)
5052 Aluminum (available in Sheet)
6061 Aluminum (available in Angle, Channel, I-Beam, Pipe, Plate, Rectangle, Round, Sheet, Square, Tube)
6063 Aluminum (available in Angle, Channel, Rectangle Tube, Square Tube)
7075 Aluminum (available in Plate, Round, Sheet)
2011 Aluminum
2011 is the most machinable of the commonly available aluminum alloys. Machining this alloy can produce excellent surface finishes on your product, and small, broken chips.
Weldability, strength, and anodizing response are all rated as average at best, and this alloy does not have a high degree of corrosion resistance.
If the ability to make your part quickly is important to you, and strength is not the primary desire, 2011 represents a good choice if you're using aluminum.
2011-T3 Aluminum
Minimum Properties Ultimate Tensile Strength, psi 55,000
Yield Strength, psi 43,000
Brinell Hardness 95
Rockwell Hardness B60
Chemistry Aluminum (Al) 91.2 - 94.6%
Bismuth (Bi) 0.2 - 0.6%
Copper (Cu) 5.0 - 6.0%
Iron (Fe) 0.7% max
Magnesium (Mg) 2.1 - 2.9%
Lead (Pb) 0.2 - 0.6%
Silicon (Si) 0.4% max
2024 Aluminum
Copper is the main alloying ingredient in 2024. It is very strong compared to most aluminum alloys, and has average machinability, but the copper component of this alloy makes it susceptible to corrosion (many items in this alloy are produced with a clad surface to protect the underlying material.) In addition, 2024 is not considered to be weldable.
Finally, the fatigue resistance of 2024 make it a primary choice when the application is expected to be under stress or strain for prolonged periods. It is commonly used in aerospace applications.
2024-T3 Aluminum
Minimum Properties Ultimate Tensile Strength, psi 70,000
Yield Strength, psi 50,000
Brinell Hardness 120
Rockwell Hardness B75
Chemistry Aluminum (Al) 90.7 - 94.7%
Chromium (Cr) 0.1% max
Copper (Cu) 3.8 - 4.9%
Iron (Fe) 0.5% max
Magnesium (Mg) 1.2 - 1.8%
Manganese (Mn) 0.3 - 0.9%
Silicon (Si) 0.5% max
5052 Aluminum
5052 is the alloy most suited to forming operations, with good workability and higher strength than that of the 1100 or 3003 alloys that are commercially available.
5052 is not heat-treatable, but is stronger than most of the 5xxx series of alloys. It has very good corrosion resistance, and can be easily welded. 5052 is not a good choice for extensive machining operations, as it has only a fair machinability rating.
5052-H32 Aluminum
Minimum Properties Ultimate Tensile Strength, psi 33,000
Yield Strength, psi 28,000
Brinell Hardness 60
Chemistry Aluminum (Al) 95.7 - 97.7%
Chromium (Cr) 0.15 - 0.35%
Copper (Cu) 0.1% max
Iron (Fe) 0.4% max
Magnesium (Mg) 2.2 - 2.8%
Manganese (Mn) 0.1% max
Silicon (Si) 0.25% max
6061 Aluminum
6061 Aluminum is, by most any measure, the most commonly used aluminum alloy. It is specified in most any application due to its strength, heat treatability, comparatively easy machining, and weldability. If that were not enough, it is also capable of being anodized, adding a layer of protection for finished parts.
The main alloy ingredients of 6061 aluminum are magnesium and silicon.
6061-T6 Aluminum
Physical and Mechanical Properties Ultimate Tensile Strength, psi 45,000
Yield Strength, psi 40,000
Brinell Hardness 95
Rockwell Hardness B60
Chemistry Aluminum (Al) 95.8 - 98.6%
Chromium (Cr) 0.04 - 0.35%
Copper (Cu) 0.15 - 0.40%
Magnesium (Mg) 0.8 - 1.2%
Manganese (Mn) 0.15% max
Silicon (Si) 2.8 - 3.8%
Zinc (Zn) 1.5% max
6063 Aluminum
6063 is often called architectural aluminum for two reasons - first, it has a surface finish that is far smoother than the other commercially available alloys, and second, its strength is significantly less (roughly half the strength of 6061), making it suited for applications where strength is not the foremost consideration.
6063 is rated as "Good" for forming and cold working operations, "Excellent" for anodizing, and "Fair" for machining.
6063-T52 Aluminum
Minimum Properties Ultimate Tensile Strength, psi 27,000
Yield Strength, psi 21,000
Brinell Hardness 60
Chemistry Aluminum (Al) 97.5% max
Chromium (Cr) 0.1% max
Copper (Cu) 0.1% max
Iron (Fe) 0.35% max
Magnesium (Mg) 0.45 - 0.90%
Manganese (Mn) 0.1% max
Silicon (Si) 0.2 - 0.6%
7075 Aluminum
7075 is the other "aircraft grade" aluminum that is carried by OnlineMetals. Its principal alloying ingredients are Zinc and copper, which make it one of the highest-strength aluminum alloys that are available. In fact, its typical strength in the T6 temper is higher than most mild steels.
7075 also has average-to-good ratings for machinability, corrosion resistance, and anodizing response. Like 2024, however, it is not considered to be weldable. 7075-T6 Aluminum
Physical and Mechanical Properties Ultimate Tensile Strength, psi 83,000
Yield Strength, psi 73,000
Brinell Hardness 150
Rockwell Hardness B87
Chemistry Aluminum (Al) 87.1 - 91.4%
Zinc (Zn) 5.1 - 6.1% max
Copper (Cu) 1.2 - 2.0%
Chromium (Cr) 0.18 - 0.28%
Iron (Fe) 0.5 max
Magnesium (Mg) 2.1 - 2.9%
Manganese (Mn) 0.3% max
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Im no expert, but im trying to help you in your endeavor, so that you dont get taken advantage of, and so your prepared to move fast when you find your outlet.
Ill try to get you in contact with my client.
Mason