Santa Please Stop Here Sign
Design process – Fusion 360
- Modelled a 12” x 30” x ¾” board.
- Imported free svg file from Free Design Resources | Download Free Graphics, SVGs, Icons + More! (designbundles.net)
- Sized the svg file 1.5 inches smaller than the board.
- Removed border from svg file.
- Cut svg shapes into the board, 1/32” deep.
Creating Tool Paths – Fusion 360
- Setup board 12” x 30” x ¾” in manufacturing workspace.
- Cut Santa and sleigh using 2D pocket command with 1/16” down cut end mill. Spindle speed 20,000 RPM, feed rate 60 inches/minute. Multiple cuts 0.04” deep.
- Cut the words; PLEASE, STOP and here using 2D pocket command with 1/16” down cut end mill. Spindle speed 20,000 RPM, feed rate 60 inches/minute. Multiple cuts 0.04” deep.
- Cut the shapes using engrave command, with 90-degree V groove router bit. Spindle speed 20,000 RPM, feed rate 60 inches/minute.
- Cut the words; Santa Claus using engrave command, with 90-degree V groove router bit. Spindle speed 20,000 RPM, feed rate 60 inches/minute.
- Cut the outline using 2D contour command with ¼” compression end mill. Tabs added. Spindle speed 20,000 RPM, feed rate 60 inches/minute. Multiple cuts 0.12” deep.
- Created tool paths using the Fusion 360 post process feature.
Manufacturing – Longmill 30 x 30, with Makita Router – UGS software
- Clamped 12” x 30” board into Longmill using screws. Screw heads counterbored down at least ¼” each.
- Surfaced board using ½” surfacing bit. Jogged router.
- Sanded surface slightly.
- Painted surface white.
- Waited approximately 24 hours for paint to dry.
- Applied Oramask 813.
- Cut all tool paths as outlined in tool path section above.
- Removed board from Longmill.
- Painted letter and shape areas with green and red paint.
- Removed Oramask.
- Touched up a few areas with paints.
- Created frame separately using table saw and router.
- Added frame to sign.
- Finished with polyurethane.
- Added lights.
Problems
- Didn’t wait long enough for white paint to dry before applying Oramask. Result was very sticky surface that attracted all kinds of dirt.
- Didn’t wait long enough for red paint to dry before applying polyurethane. Result was that the red paint smeared. Had to repaint white areas around red features.
